This procedure covers the removal and replacement of the outer tie rod end assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD, including proper torque specifications and alignment considerations.

Warnings

Tools required

Parts

• Tie rod end (outer) × 1 — 56820-D3000 or aftermarket equivalent
• Cotter pin × 1 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and support with jack stands at manufacturer-specified lift points
5. Remove wheel completely
6. Spray tie rod end components with penetrating oil and allow to soak for 10-15 minutes if corrosion is present

Procedure

1. 1

   Mark tie rod position
   Before loosening any components, use a white paint marker or grease pencil to mark the exact position of the outer tie rod end on the threaded inner tie rod shaft. Make alignment marks across both the lock nut and the tie rod body. Count and record the number of exposed threads beyond the outer tie rod end. This ensures approximate toe alignment during reassembly.
2. 2

   Remove cotter pin and castle nut
   Use pliers to straighten and remove the cotter pin from the tie rod end castle nut. Discard the old cotter pin. Using a 19mm socket, loosen but do not fully remove the tie rod end castle nut. Leave the nut threaded on by 2-3 turns to protect the threads and prevent the tie rod from falling when separated.
3. 3

   Separate tie rod end from knuckle
   Using a tie rod end separator tool or pickle fork, insert the tool between the steering knuckle and the tie rod end ball joint taper. Strike the tool firmly with a hammer or apply pressure according to tool design until the taper releases with a pop. If using a pickle fork, position it to avoid damaging adjacent boots. Once separated, remove the castle nut completely and pull the tie rod end stud out of the knuckle.
   ⚠Keep hands clear of tie rod end when striking separator tool as component may release suddenly.
4. 4

   Loosen tie rod lock nut
   Using a 21mm wrench, loosen the lock nut that secures the outer tie rod end to the inner tie rod shaft. Do not remove the lock nut completely; instead, thread it toward the outer tie rod end to keep it on the assembly. Note the position relative to your alignment marks.
5. 5

   Remove outer tie rod end
   While holding the lock nut in place, unthread the outer tie rod end from the inner tie rod shaft by rotating it counterclockwise. Count the number of complete rotations required for removal and record this number. Remove both the tie rod end and lock nut from the shaft. Clean the threads on the inner tie rod shaft with a wire brush to remove dirt and corrosion.
6. 6

   Install new outer tie rod end
   Thread the lock nut onto the inner tie rod shaft first, positioning it near the outer end. Apply a small amount of thread locker to the first few threads of the inner tie rod shaft. Thread the new outer tie rod end onto the inner tie rod shaft clockwise, matching your previous rotation count and alignment marks as closely as possible. The tie rod should thread on to approximately the same position as the old one.
7. 7

   Install tie rod end into knuckle
   Insert the tie rod end ball stud into the steering knuckle taper hole. Ensure the taper is clean and free of debris. Thread the castle nut onto the ball stud and tighten to specification. Align the castle nut slots with the ball stud hole by tightening only (never loosen to align). Install a new cotter pin through the castle nut and ball stud, then bend the ends of the cotter pin to secure.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
8. 8

   Temporarily secure lock nut
   Hand-tighten the tie rod lock nut against the outer tie rod end body, but do NOT torque to final specification yet. The lock nut must only be torqued to final specification after a professional wheel alignment is performed. Mark the lock nut position with paint to verify it remains in place until alignment.
   ⚠Do not apply final torque to lock nut until after alignment is complete. Final torque is 68 Nm (50 lb-ft).
9. 9

   Reinstall wheel
   Position the wheel onto the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the wheel lug nuts to specification in a star pattern to ensure even seating.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
10. 10

    Lower vehicle and final check
    Fully lower the vehicle to the ground and remove jack stands. Perform a final torque verification on wheel lug nuts. Rock the steering wheel gently left and right to ensure tie rod end is properly seated and moves smoothly without binding or noise.

Reassembly

1. Verify new cotter pin is properly installed and bent to prevent removal
2. Ensure no tools or parts were left in the wheel well area
3. Check that all fasteners are tight and properly torqued except the tie rod lock nut which awaits alignment

Verification

• Test drive vehicle at low speed in a safe area to verify steering response and no unusual noises
• Verify no play or looseness in the tie rod end by having an assistant turn the steering wheel while you inspect the connection at the knuckle
• Schedule a professional wheel alignment immediately - the tie rod lock nut final torque of 68 Nm (50 lb-ft) must be applied AFTER alignment adjustment
• After alignment, verify the technician torqued the tie rod lock nut to specification
• Monitor tire wear pattern over the next 500 miles to confirm proper alignment

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