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

Warnings

Tools required

Parts

• Rear sway bar × 1 — Use OEM specification
• Sway bar bushings × 2 — Use OEM specification
• Sway bar link nuts (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise rear of vehicle with floor jack at manufacturer-specified lift points
5. Support vehicle securely on jack stands positioned under rear subframe or axle mounting points
6. Remove both rear wheels completely
7. Spray penetrating oil on sway bar link nuts and bracket bolts if corrosion is present, allow 10-15 minutes to penetrate

Procedure

1. 1

   Access the rear sway bar
   Locate the rear sway bar running laterally across the rear suspension. Identify the two sway bar links connecting the bar to the rear suspension arms and the two mounting brackets securing the bar to the subframe or body.
2. 2

   Disconnect driver side sway bar link
   Insert a 6mm Allen key into the shaft end of the sway bar link stud to hold it stationary. Using a 17mm socket, remove the upper nut connecting the link to the sway bar. Note the position and orientation of any washers or bushings for reassembly.
   Torque spec

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

   Disconnect passenger side sway bar link
   Repeat the link disconnection process on the passenger side. Insert the 6mm Allen key into the shaft and remove the upper nut with a 17mm socket. Allow both links to hang from the suspension arms.
4. 4

   Remove driver side mounting bracket
   Locate the sway bar mounting bracket on the driver side. Using a 14mm socket, remove the two bolts securing the bracket to the subframe or body. Remove the bracket and carefully extract the rubber bushing from the sway bar, noting its orientation and any alignment marks.
   Torque spec

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

   Remove passenger side mounting bracket
   Using a 14mm socket, remove the two bolts securing the passenger side mounting bracket. Remove the bracket and bushing. The sway bar should now be completely free.
   Torque spec

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

   Remove the sway bar
   Carefully maneuver the sway bar out from between the suspension components. It may need to be rotated or angled to clear the suspension arms and exhaust components. Take note of the routing path for installation of the new bar.
7. 7

   Prepare new sway bar
   Install the new rubber bushings onto the new sway bar in the correct orientation. The split in the bushing should face toward the front or rear of the vehicle as noted during removal. Ensure bushings are positioned at the same locations as the original bar, typically marked by indentations or paint marks on the bar.
8. 8

   Install new sway bar
   Route the new sway bar into position following the same path as removal. Ensure the bar is centered with equal length extending on both sides and the bushings are aligned with the mounting bracket locations.
9. 9

   Install mounting brackets
   Position the mounting brackets over the bushings on both sides. Start all four bracket bolts by hand to ensure proper threading. Tighten the bracket bolts to specification using a torque wrench and 14mm socket.
   ⚠Ensure the bushing split is oriented correctly and the bushing is fully seated in the bracket before torquing bolts.
   Torque spec

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

    Connect sway bar links
    Align the sway bar link studs with the holes in the sway bar ends on both sides. Install any washers and bushings in the correct order as noted during removal. Thread the nuts onto the studs by hand. Hold each link shaft with the 6mm Allen key and torque the nuts to specification using a 17mm socket and torque wrench.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Reinstall wheels
    Install both rear wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque lug nuts to manufacturer specification (typically 107-127 Nm / 79-94 lb-ft) in a star pattern. Fully lower vehicle and remove jack stands.

Reassembly

1. Verify all fasteners have been torqued to specification
2. Confirm sway bar links move freely without binding
3. Check that no tools or parts were left in the work area

Verification

• Test drive the vehicle at low speed in a safe area and verify no abnormal noises from the rear suspension
• Perform a gentle slalom maneuver to ensure the sway bar is functioning and reducing body roll
• Visually inspect underneath the vehicle after test drive to confirm no loose components or unusual wear patterns
• Listen for any clunking or rattling sounds over bumps that would indicate loose or improperly installed components

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