This procedure covers the removal and replacement of the upper steering shaft on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, addressing common issues like clunking or binding during steering input.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM specification
• Steering shaft coupler bolt (if reusable bolt not recommended) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position with front wheels pointing straight ahead
4. Turn ignition off and remove key
5. Disconnect negative battery terminal and wait at least 3 minutes before proceeding (airbag system discharge)
6. Raise front of vehicle and support on jack stands at manufacturer-specified jacking points
7. Remove front wheels if additional access is needed for lower shaft inspection

Procedure

1. 1

   Remove driver lower dash trim panel
   Remove the screws securing the lower driver side dashboard panel below the steering column. Carefully pull the panel away from the dashboard to release any retaining clips. Disconnect any electrical connectors for diagnostic port or other components as needed. Set panel aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Access upper steering shaft
   Locate the upper steering shaft connection point above the firewall inside the cabin. You should see the upper shaft connected to the lower shaft via a coupler joint with a pinch bolt. Remove any additional trim or insulation covering the steering shaft if present.
3. 3

   Mark shaft alignment
   Using a white paint pen or marking tool, make alignment marks across the upper and lower steering shaft coupler joint. Mark both the shaft and coupler in at least two locations to ensure proper reinstallation alignment. This is critical for maintaining steering wheel center position.
   ⚠Accurate alignment marks are essential. Improper alignment will result in off-center steering wheel position.
4. 4

   Disconnect lower shaft coupler
   Locate the pinch bolt securing the upper shaft to the lower shaft coupler (typically accessed from under the dashboard). Loosen and remove the pinch bolt completely. Use a flat blade screwdriver to carefully spread the coupler slot slightly if needed to separate the shafts. Do not force separation; apply penetrating lubricant if binding occurs.
   ⚠Support the lower shaft to prevent it from dropping or rotating once disconnected.
5. 5

   Remove upper shaft mounting fasteners
   Locate the mounting bolts securing the upper steering shaft bracket to the firewall or column support bracket inside the cabin. Remove these mounting bolts completely. Note the position and orientation of any spacers, washers, or alignment dowels for reassembly.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Remove upper steering shaft
   Carefully slide the upper steering shaft assembly upward and away from the lower shaft splines. Maneuver the shaft out of the steering column area, being careful not to damage surrounding components, wiring, or trim. Inspect the removed shaft for wear, binding, corrosion, or damaged universal joints.
7. 7

   Inspect lower shaft and coupler
   With upper shaft removed, inspect the lower shaft coupler for wear, damage, or elongated splines. Check that the lower shaft has not rotated from its centered position. If it has rotated, you will need to re-center the steering system before installing the new upper shaft.
   ⚠If lower shaft has rotated, consult service manual for clockspring centering procedure before proceeding.
8. 8

   Install new upper steering shaft
   Position the new upper steering shaft assembly into the steering column area. Align the shaft with the mounting bracket on the firewall or column support. Install mounting bolts finger-tight initially to allow for alignment adjustment. Ensure any alignment dowels are properly seated.
9. 9

   Torque upper shaft mounting bolts
   Once the upper shaft is properly positioned and aligned, torque the mounting bolts to specification using a calibrated torque wrench. Verify shaft moves freely without binding through its full range of motion before proceeding.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Connect upper shaft to lower shaft
    Align the splines of the upper steering shaft with the lower shaft coupler, carefully matching the alignment marks made during disassembly. Slide the shafts together fully, ensuring complete engagement of splines. The coupler pinch bolt hole should align properly when shafts are correctly positioned.
    ⚠Verify alignment marks match exactly before installing pinch bolt to ensure steering wheel remains centered.
11. 11

    Install and torque coupler pinch bolt
    Insert the coupler pinch bolt through the coupler and shaft. If using a new bolt (recommended by some manufacturers), ensure it is the correct specification. Tighten the pinch bolt firmly. Note: Specific torque for this pinch bolt is not provided in database; consult factory service manual for exact specification, typically 20-30 Nm range for this component.
    ℹ️Pinch bolt torque specification not in provided database. Consult factory service manual for exact value.
12. 12

    Verify shaft operation
    With the shaft connected, manually rotate the steering shaft slightly (no more than 15 degrees in either direction) to verify smooth operation without binding or unusual resistance. Check that all connections are secure and alignment marks remain matched.
13. 13

    Reinstall dash trim and components
    Reconnect any electrical connectors that were disconnected. Position the lower dash trim panel back into place, ensuring all retaining clips engage properly. Install and torque the trim panel screws to specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
14. 14

    Reconnect battery and finalize
    Reconnect the negative battery terminal. If front wheels were removed, reinstall them and torque lug nuts to specification in a star pattern. Lower vehicle from jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all alignment marks on steering shafts remain properly matched throughout installation
2. Verify all mounting fasteners are torqued to specification
3. Do not skip battery disconnect waiting period (3 minutes minimum) to ensure airbag system safety
4. Double-check that steering wheel remains centered after installation

Verification

• Start engine and verify no warning lights related to steering or airbag systems appear on instrument cluster
• Turn steering wheel lock-to-lock while stationary to confirm smooth operation without binding, clicking, or clunking
• Verify steering wheel is centered when front wheels are pointing straight ahead
• Test drive vehicle at low speed in safe area, checking for proper steering response and absence of abnormal noises
• Confirm steering wheel returns to center properly after turns
• Re-check pinch bolt and mounting bolt tightness after test drive

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