This procedure covers the replacement of the rear sway bar bushings on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, which involves removing the sway bar bracket bolts and replacing the worn bushings.

Warnings

Tools required

Parts

• Rear sway bar bushing set (2 pieces) × 1 — Use OEM specification - typically part of bushing kit

Preparation

1. Park vehicle on level ground and set parking brake
2. Place wheel chocks in front of front wheels
3. If bushings are rusted, spray sway bar bracket bolts with penetrating oil and let soak for 10-15 minutes

Procedure

1. 1

   Raise and support vehicle
   Raise the rear of the vehicle using a floor jack at the rear differential or designated lift point. Once at working height, place jack stands under the rear subframe or pinch welds on both sides. Lower the vehicle onto the jack stands and verify stability before working underneath.
2. 2

   Locate rear sway bar and bushings
   From under the vehicle, locate the rear sway bar running laterally across the rear suspension. Identify the two bushing bracket assemblies that secure the sway bar to the rear subframe or chassis. Note the orientation of the bushing split (typically faces toward the rear or front of vehicle).
3. 3

   Remove sway bar bracket bolts
   Using the appropriate socket (typically 12mm or 14mm), remove the two bolts securing each sway bar bracket to the subframe. There are four bolts total (two per bracket). Support the sway bar with one hand as you remove the final bolts to prevent it from dropping. Remove both brackets.
   Torque spec

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

   Remove old bushings
   Remove the old bushings from the sway bar. If the bushings are split (most common), they should pull apart easily. If they are stuck or deteriorated, carefully cut them away with a utility knife, being careful not to score the sway bar surface. Clean the sway bar mounting surface with a wire brush to remove any rust, debris, or old rubber residue.
5. 5

   Install new bushings
   Position the new bushings onto the sway bar in the same location as the old bushings. Ensure the split in the bushing faces the correct direction (typically rearward). The bushings should seat fully around the bar. If the bushings have a locating tab or notch, align it with the corresponding feature on the bracket.
6. 6

   Reinstall sway bar brackets
   Place the sway bar brackets over the new bushings, aligning the bracket holes with the threaded holes in the subframe. Start all four bracket bolts by hand to ensure proper thread engagement. The brackets should compress the bushings evenly when tightened.
7. 7

   Torque bracket bolts to specification
   Using a torque wrench, tighten the sway bar bracket bolts to 47.0 Nm (35.0 lb-ft) in a cross-pattern (tighten one bolt partially on each bracket, then the other, alternating until fully torqued). This ensures even compression of the bushings and proper sway bar alignment.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
8. 8

   Lower vehicle and verify installation
   Raise the vehicle slightly off the jack stands, remove the stands, and carefully lower the vehicle to the ground. Rock the vehicle side-to-side gently to allow the suspension to settle and verify there are no unusual noises from the rear sway bar area.

Reassembly

1. Ensure all sway bar bracket bolts are torqued to specification
2. Verify bushings are properly seated and brackets are secure before driving

Verification

• Start the vehicle and turn the steering wheel full lock in both directions while stationary - there should be no clunking from the rear
• Test drive the vehicle over minor bumps and through turns at low speed, listening for any rattling or clunking noises from the rear suspension
• After 50-100 miles of driving, re-check sway bar bracket bolt torque to ensure they have not loosened

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