This procedure covers removal and replacement of a door speaker on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Replacement door speaker × 1 — Use OEM specification for model year and door location
• Door panel clips × 5 — Keep spares on hand, may break during removal

Preparation

1. Park vehicle on level surface and engage parking brake
2. Roll down window approximately 2-3 inches to prevent glass damage during panel removal
3. Disconnect battery negative terminal and wait 3 minutes for airbag system discharge
4. Identify which door speaker requires replacement (front or rear, driver or passenger)

Procedure

1. 1

   Remove door panel screws
   Locate and remove all visible Phillips screws securing the door panel. On 2016-2024 Tucson models, there is typically one screw behind the door handle pull cup and one in the lower rear corner of the panel. Some models may have a screw inside the speaker grille cover itself.
2. 2

   Remove door handle trim and window switch assembly
   Use a panel removal tool to carefully pry up the window switch assembly from the armrest. Disconnect the electrical connector by pressing the release tab and pulling straight up. On models with memory seats, there may be an additional connector for the mirror controls.
3. 3

   Release door panel clips
   Starting at the bottom rear corner, use a trim clip removal tool to gently pry the door panel away from the door frame. Work your way around the perimeter, releasing each clip carefully. The Tucson typically uses 8-12 push-type clips around the panel edge. Listen for the click as each clip releases.
4. 4

   Disconnect door panel electrical connectors
   With the panel partially separated, locate and disconnect any remaining electrical connectors including tweeter speaker wires (if equipped), door latch cable, and courtesy light connector. Note the routing of the door latch cable before disconnecting.
5. 5

   Remove door panel completely
   Lift the door panel upward to disengage it from the window sill channel, then pull away from the door. Set the panel on a protected surface with the interior side facing up to prevent scratching.
6. 6

   Peel back vapor barrier
   Carefully peel back the plastic vapor barrier sheet around the speaker location. The barrier is typically held with butyl adhesive. Only remove enough to access the speaker mounting area, keeping the barrier intact for proper resealing.
7. 7

   Disconnect speaker wiring harness
   Locate the speaker electrical connector and press the release tab while pulling the connector apart. Note the wire routing and any clips securing the harness to the door frame.
8. 8

   Remove speaker mounting fasteners
   Remove the speaker mounting screws (typically 3-4 screws) securing the speaker to the door frame. On Tucson models, these are usually Phillips head screws. If the speaker is mounted with bolts rather than screws, use appropriate torque specifications on reinstallation.
9. 9

   Extract speaker from door
   Carefully pull the speaker out of the door cavity, tilting as needed to clear the mounting hole. Note the orientation of the speaker and any foam sealing gaskets or spacers that may be present.
10. 10

    Install new speaker
    Position the new speaker in the door cavity with the correct orientation, ensuring any foam gaskets are properly seated. Thread the wiring harness through to the connector location. Align the speaker mounting holes with the door frame.
11. 11

    Secure speaker mounting fasteners
    Install all speaker mounting screws and tighten in a cross pattern to ensure even seating. Tighten screws firmly but do not over-torque as the mounting tabs can crack. If using screws into plastic, hand-tight plus 1/4 turn is appropriate.
12. 12

    Connect speaker wiring and test
    Connect the speaker wiring harness until it clicks into place. Temporarily reconnect the battery negative terminal and turn the ignition to ACC position. Test speaker function using the audio system, checking all channels and balance settings to verify proper operation. Disconnect battery again before continuing.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
13. 13

    Reseal vapor barrier
    Press the vapor barrier back into position, ensuring complete adhesion around the speaker area. Add fresh butyl tape or weather strip adhesive if the original adhesive has lost its tackiness. The barrier must seal completely to prevent water intrusion and wind noise.

Reassembly

1. Reconnect all door panel electrical connectors in reverse order of removal, ensuring each connector clicks securely into place
2. Reattach the door latch cable to the handle mechanism, verifying proper routing
3. Align the door panel with the window sill channel and lower into position before pressing against the door frame
4. Press firmly around the panel perimeter to seat all push clips, working from center outward
5. Reinstall all door panel screws and tighten to secure the panel
6. Install window switch assembly and door handle trim pieces
7. Reconnect battery negative terminal and tighten to 6.0 Nm (4.0 lb-ft) as specified
8. Reset window auto-up/auto-down function by fully opening window, then fully closing and holding switch for 2 seconds

Verification

• Turn ignition to ACC and test speaker at various volume levels across full frequency range
• Test audio balance and fader controls to verify speaker responds correctly to all channels
• Check for rattles or vibrations by playing bass-heavy audio at moderate to high volume
• Verify all door panel functions: window switches, door lock, mirror controls all operate normally
• Inspect door panel fitment around all edges, ensuring uniform gaps and no loose areas
• Open and close door several times to verify panel does not shift or make noise
• Check that door panel clips are fully seated by pressing around perimeter and listening for any movement

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