This procedure covers the removal and replacement of the front sway bar (stabilizer bar) on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD.

Warnings

Tools required

Parts

• Front sway bar × 1 — Use OEM specification
• Sway bar bushings × 2 — Use OEM specification
• Sway bar bracket bolts × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely with jack stands on manufacturer lift points
5. Remove both front wheels completely
6. Spray penetrating oil on sway bar link nuts and bracket bolts, allow to soak for 10-15 minutes if fasteners show corrosion

Procedure

1. 1

   Disconnect driver side sway bar link
   Locate the sway bar link connecting the sway bar to the lower control arm on the driver side. Insert a 6mm Allen key into the top of the link shaft to hold it stationary. Using a 14mm socket, remove the lower nut connecting the link to the sway bar. Separate the link from the sway bar.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Disconnect passenger side sway bar link
   Repeat the same process on the passenger side. Insert the 6mm Allen key into the link shaft to prevent rotation. Remove the lower nut with a 14mm socket and separate the link from the sway bar. Allow both links to hang from the control arms.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove driver side sway bar bracket
   Locate the sway bar bracket bolted to the subframe on the driver side. The bracket secures the sway bar bushing. Using a 14mm socket, remove both bracket bolts. Remove the bracket and note the orientation of the bushing split for reinstallation.
   Torque spec

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

   Remove passenger side sway bar bracket
   Repeat the process on the passenger side. Remove both bracket bolts with a 14mm socket and remove the bracket. Keep brackets and hardware organized by side if they show any differences.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
5. 5

   Remove sway bar from vehicle
   With both brackets removed, maneuver the sway bar downward and toward one side to clear the subframe. The bar may need to be rotated or angled to clear suspension components and steering linkage. Remove the old bushings from the sway bar and inspect for wear or cracking.
   ⚠Sway bar weighs approximately 15-20 lbs. Use proper lifting technique to avoid strain.
6. 6

   Inspect and clean mounting areas
   Clean the sway bar mounting points on the subframe with a wire brush to remove rust and debris. Inspect the subframe for cracks or damage. Check sway bar link condition - replace if rubber boots are torn or if there is excessive play in the ball joints.
   ℹ️This is the ideal time to replace worn sway bar links if needed.
7. 7

   Install new bushings on sway bar
   Slide the new sway bar bushings onto the bar at the marked locations (or match the position of the old bushings). Ensure the split in the bushing faces toward the rear of the vehicle when installed. Apply a light coating of silicone grease to the inside of the bushings if they are difficult to slide into position.
   ℹ️Do not use petroleum-based lubricants on rubber bushings as they cause deterioration.
8. 8

   Position sway bar in vehicle
   Maneuver the sway bar into position by angling it up through the suspension area. Align the bushings with the mounting points on the subframe. Ensure the bar ends are positioned correctly to connect to the sway bar links on both sides.
   ⚠Verify bar orientation - the bend angles should match the original bar position.
9. 9

   Install driver side bracket
   Position the bracket over the bushing on the driver side, ensuring the bushing split faces rearward. Start both bracket bolts by hand to ensure proper thread engagement. Tighten the bolts to the specified torque in a cross pattern.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
10. 10

    Install passenger side bracket
    Position the bracket over the bushing on the passenger side with the bushing split facing rearward. Install both bracket bolts and tighten to specification in a cross pattern to ensure even bushing compression.
    Torque spec

    Sway Bar Bracket Bolts47 Nm (35 lb-ft)
11. 11

    Connect driver side sway bar link
    Align the sway bar link ball stud with the hole in the end of the sway bar on the driver side. Install the nut and hand-tighten. Insert the 6mm Allen key into the top of the link shaft to hold it stationary, then torque the nut to specification using a 14mm socket.
    Torque spec

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

    Connect passenger side sway bar link
    Repeat the connection process on the passenger side. Align the link to the sway bar, install the nut, hold the shaft with the Allen key, and torque the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the wheels just touch the ground but the suspension is not yet loaded. Torque the lug nuts to 107-127 Nm (79-94 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. All fasteners should be torqued to specification with the vehicle at normal ride height (wheels on ground) where noted
2. Verify all sway bar link nuts are properly torqued with the Allen key holding the shaft
3. Ensure no tools or parts are left in the wheel wells before test driving

Verification

• Bounce each front corner of the vehicle and listen for any clunking or rattling from the sway bar area
• Test drive the vehicle at low speed and verify no unusual noises during turns or over bumps
• Perform a figure-8 maneuver in an empty parking lot to verify proper sway bar function and connection
• Re-check all bracket bolt and link nut torque after 50-100 miles of driving

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