This procedure covers the removal and replacement of worn subframe bushings on the front or rear subframe of a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Front or rear subframe bushings (set of 4) × 1 — Use OEM specification
• Subframe mounting bolts (if corroded) × 4 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove wheels
6. Spray all subframe mounting bolts and bushing areas with penetrating oil
7. Mark subframe position relative to body using paint pen or scribe for alignment reference during reinstallation

Procedure

1. 1

   Remove underbody panels and heat shields
   Remove all plastic underbody panels and any heat shields that obstruct access to the subframe mounting bolts. These are typically held by 10mm bolts and plastic clips. Store fasteners in a labeled container.
2. 2

   Disconnect affected suspension components
   Depending on which subframe (front or rear) you are servicing, disconnect the lower control arms from the ball joints or knuckles. Remove the cotter pins and loosen the ball joint nuts. Use a ball joint separator if necessary. For rear subframe work, support the rear differential with a jack before proceeding.
   ⚠Do not allow suspension components to hang unsupported by their brake lines or ABS sensors. Use wire or straps to support components.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Disconnect sway bar links if applicable
   If the sway bar links attach to the subframe or will interfere with subframe lowering, disconnect them at the appropriate end. Hold the shaft with an Allen key while removing the nuts to prevent spinning.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Support the subframe
   Position a hydraulic transmission jack or multiple adjustable support stands under the subframe. Ensure the subframe is fully supported and stable before proceeding. The subframe is heavy and will drop once the mounting bolts are removed.
   ⚠️The subframe weighs approximately 50-80 lbs and may shift unexpectedly. Ensure adequate support before removing mounting bolts.
5. 5

   Remove subframe mounting bolts
   Locate all four subframe mounting bolts (typically 17mm or 19mm heads). Remove the bolts gradually in a cross pattern, loosening each bolt partially before fully removing any bolt. This prevents binding and allows the subframe to lower evenly. Keep track of any shims or alignment washers.
   ⚠On AWD models, ensure the driveshaft and differential are adequately supported and will not be damaged as the subframe lowers.
6. 6

   Lower the subframe
   Carefully lower the transmission jack or support stands to drop the subframe approximately 3-6 inches. Lower only enough to access the bushings. Check for any remaining connections (brake lines, wiring harnesses, fuel lines) that may be attached or routed near the subframe.
7. 7

   Remove old bushings
   Using a bushing press tool or hydraulic press, press out the old bushings from the subframe. Note the orientation of each bushing (voids or slots in the rubber should align in specific directions). Clean the bushing bores thoroughly with a wire brush and inspect for cracks or damage.
   ℹ️Take photos of bushing orientation before removal. Incorrect orientation can affect ride quality and handling.
8. 8

   Install new bushings
   Apply a thin layer of soapy water or bushing installation lubricant to the new bushings (do not use petroleum-based lubricants). Press the new bushings into the subframe bores using the bushing press tool, ensuring proper orientation matches the original configuration. Bushings should be fully seated and flush with the subframe mounting surface.
9. 9

   Raise and align the subframe
   Carefully raise the subframe back into position using the transmission jack. Use your alignment reference marks to position the subframe correctly. This is critical for proper wheel alignment. Insert alignment tools or pry bars as needed to shift the subframe into exact position before installing bolts.
   ⚠Subframe misalignment will cause incorrect wheel alignment and premature tire wear. Take time to align properly using reference marks.
10. 10

    Install subframe mounting bolts
    Install all four subframe mounting bolts with any original shims or washers. Thread bolts by hand first to ensure proper threading. Tighten bolts gradually in a cross pattern to draw the subframe up evenly. Torque all mounting bolts to the specification provided in your service manual (typically 150-200 Nm, but verify for your specific model year as this torque is not listed in the provided specifications).
    ℹ️Subframe mounting bolt torque specification is not provided in this database. Consult factory service manual for exact specification - typically 150-200 Nm.
11. 11

    Reconnect suspension components
    Reconnect the lower control arms to the ball joints or knuckles. Install new cotter pins if equipped. Reconnect sway bar links if previously removed, holding the shaft with an Allen key while tightening.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

    Reinstall heat shields and underbody panels
    Reinstall all heat shields and plastic underbody panels in reverse order of removal. Ensure all clips and fasteners are properly secured.
13. 13

    Install wheels and lower vehicle
    Install wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground but the suspension is not fully loaded. Torque lug nuts to specification in a star pattern. Then fully lower the vehicle.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
14. 14

    Torque control arm bolts with vehicle weight on wheels
    With the vehicle at normal ride height and weight on the wheels, torque the control arm bolts to specification. This is critical - torquing suspension bushings with the suspension hanging will cause premature bushing failure and binding.
    ⚠Control arm bolts MUST be torqued with vehicle at ride height. Failure to do so will cause bushing binding and premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification and all cotter pins are installed where applicable
2. Verify no tools or parts were left in the wheel wells or under the vehicle
3. Check that all underbody panels are securely fastened

Verification

• Test drive the vehicle at low speed in a safe area and listen for any unusual noises or clunking from the suspension
• Check for proper steering response and verify the vehicle tracks straight
• Schedule a professional wheel alignment within 24 hours of completing this repair, as subframe removal will affect alignment settings
• After 50-100 miles, re-torque all subframe mounting bolts and suspension fasteners to verify they have not loosened

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