This procedure covers the replacement of front sway bar bushings on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD, requiring removal of the sway bar bracket bolts and installation of new bushings.

Warnings

Tools required

Parts

• Front sway bar bushing set (2 pieces) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground (if removing wheels for access)
4. Lift front of vehicle with floor jack at designated jacking points
5. Support vehicle on jack stands placed at manufacturer-specified support points
6. Remove front wheels if needed for better access (optional but recommended)

Procedure

1. 1

   Locate sway bar and bushings
   Position yourself under the front center of the vehicle. Locate the front sway bar running laterally across the front subframe. Identify the two sway bar bushing brackets that secure the bar to the subframe, typically positioned near the center of the vehicle width.
2. 2

   Apply penetrating oil
   Spray penetrating oil on both sway bar bracket bolts if they show signs of corrosion. Allow 5-10 minutes for penetration. This is particularly important on vehicles in rust-prone regions.
3. 3

   Remove first sway bar bracket
   Using a 14mm socket, remove the two bolts securing the first sway bar bushing bracket to the subframe. Keep the bolts and bracket together. Note the orientation of the bracket and bushing split line (typically faces rearward or downward).
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
4. 4

   Remove first bushing
   Remove the old sway bar bushing from the bracket. The bushing is split and should slide out. If stuck, use a flat-blade screwdriver to pry it open carefully. Note the positioning and orientation of the bushing for correct installation of the replacement.
5. 5

   Remove second sway bar bracket and bushing
   Repeat the removal process for the second sway bar bracket and bushing on the opposite side. Remove both bracket bolts and extract the old bushing from the bracket.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
6. 6

   Clean sway bar and brackets
   Use a wire brush to clean the sway bar surface where the bushings contact, removing any rust, dirt, or old rubber residue. Clean the inside of the bracket mounting surfaces. Ensure the sway bar surface is smooth to prevent premature bushing wear.
7. 7

   Install new bushings
   Open the split in the new bushing and position it around the sway bar in the correct location where the old bushing was removed. Ensure the bushing split line is oriented correctly (typically facing down or rearward). The bushing should sit centered on the sway bar at the bracket mounting location. Repeat for the second bushing.
8. 8

   Install brackets and torque bolts
   Place the bracket over each bushing, aligning the bolt holes with the subframe. Start both bracket bolts by hand to ensure proper thread engagement. Using a torque wrench, tighten the sway bar bracket bolts to specification in a cross pattern (alternate between bolts on each bracket). Repeat for both sides.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
9. 9

   Verify installation
   Visually inspect both bushings to ensure they are seated properly within the brackets and centered on the sway bar. Verify all bracket bolts are torqued and secure. Check that the sway bar can rotate slightly within the bushings (normal movement).

Reassembly

1. Reinstall front wheels if removed and hand-tighten lug nuts
2. Raise vehicle slightly with floor jack and remove jack stands
3. Lower vehicle completely to ground
4. Torque wheel lug nuts to specification in a star pattern (consult owner's manual for lug nut torque specification)

Verification

• Test drive the vehicle at low speeds over small bumps to verify no clunking noises from front suspension
• Perform a visual inspection under the vehicle after test drive to confirm brackets remain tight and bushings are properly seated
• Listen for elimination of any front-end rattling or clunking that was present before bushing replacement

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