This procedure covers removal and replacement of the inner tie rod end on the 2016-2024 Hyundai Tucson 2.5L AWD, requiring rack boot removal and proper alignment afterward.

Warnings

Tools required

Parts

• Inner tie rod end × 1 — Use OEM specification
• Steering rack boot/bellows × 1 — Use OEM specification
• Boot clamps (large and small) × 2 — Use OEM specification
• Cotter pin for outer tie rod × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and set parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove front wheel on affected side
5. Turn steering wheel to position tire rod assembly for easier access (turn left to work on right side, right to work on left side)

Procedure

1. 1

   Mark and measure tie rod position
   Before disassembly, measure and mark the exact position of the outer tie rod relative to the inner tie rod. Count the number of exposed threads on the inner tie rod and measure the overall length from the center of the outer tie rod ball joint to the steering rack boot. Make clear reference marks with a paint pen across the inner and outer tie rod junction. This preserves approximate toe setting.
2. 2

   Remove outer tie rod end from knuckle
   Remove the cotter pin from the outer tie rod castle nut using pliers. Remove the castle nut from the tie rod ball stud. Use a tie rod separator or pickle fork to separate the outer tie rod ball joint from the steering knuckle. Avoid damaging the knuckle threads or ball joint boot if reusing the outer tie rod.
   ⚠Do not hammer directly on the tie rod end threads. Use a proper separator tool to avoid damaging components.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Loosen tie rod lock nut
   Using a 22mm wrench, loosen the lock nut that secures the outer tie rod to the inner tie rod. Do not remove it completely yet; leave it threaded on the inner tie rod to mark the position.
   Torque spec

   Tie Rod Lock Nut68 Nm (50 lb-ft)
4. 4

   Remove outer tie rod
   Unthread the outer tie rod from the inner tie rod by turning it counterclockwise. Count the number of turns required for complete removal. Once removed, thread the lock nut back onto the inner tie rod to the same position and keep the outer tie rod for reinstallation.
5. 5

   Remove steering rack boot clamps
   Locate the large and small boot clamps securing the steering rack bellows/boot to the inner tie rod and steering rack housing. Cut or release these clamps and slide the boot away from the inner tie rod to expose the inner tie rod connection point at the steering rack.
   ℹ️The boot must be replaced during this service as clamps are typically destroyed during removal.
6. 6

   Remove inner tie rod end
   Using an inner tie rod removal tool or large adjustable wrench, grip the flats on the inner tie rod body near the steering rack. The inner tie rod is threaded onto the steering rack. Turn counterclockwise to unthread and remove the inner tie rod from the rack. If using a wrench, take care not to damage the rack housing. Some inner tie rods may have a staked area that needs to be loosened first.
   ⚠Do not allow the steering rack to turn inside the housing during inner tie rod removal. Hold the opposite tie rod if necessary to prevent rack rotation.
7. 7

   Prepare and install new inner tie rod
   Clean the threads on the steering rack with a wire brush. Inspect the rack threads for damage. Apply a small amount of medium-strength thread locker to the threads of the new inner tie rod if specified by manufacturer. Thread the new inner tie rod onto the steering rack by hand, then tighten securely using the inner tie rod tool. Torque to specification if available in service manual (typically 65-75 ft-lbs, but verify). Stake or secure per manufacturer requirements.
8. 8

   Install new steering rack boot
   Slide the new steering rack boot over the inner tie rod and position it correctly on both the rack housing and the inner tie rod body. Ensure the boot is not twisted and is seated properly in the grooves. Install new boot clamps on both the large (rack housing) and small (inner tie rod) ends. Tighten clamps securely using the appropriate tool.
9. 9

   Install outer tie rod
   Thread the outer tie rod onto the new inner tie rod the same number of turns counted during removal, aligning with your reference marks. This provides an approximate toe setting. Leave the lock nut loose at this stage.
10. 10

    Connect outer tie rod to knuckle
    Insert the outer tie rod ball stud into the steering knuckle. Install the castle nut and torque to specification. Ensure the castle nut slots align with the ball stud hole. If necessary, tighten slightly (never loosen) to achieve alignment. Install a new cotter pin and bend the ends to secure.
    ⚠Never back off the castle nut to align cotter pin holes. Only tighten further if needed.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
11. 11

    Reinstall wheel
    Reinstall the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Do not fully tighten the tie rod lock nut until after the wheel alignment is performed
2. After professional alignment, torque the tie rod lock nut to 68.0 Nm (50 lb-ft)
3. Verify all fasteners are properly torqued and cotter pins are installed
4. Test drive the vehicle in a safe area to verify steering feel and response

Verification

• Verify steering wheel returns to center after turns
• Check for any unusual noises or vibrations during steering input
• Confirm no play exists in the tie rod connection by attempting to move the wheel in/out with vehicle on ground
• Schedule and complete a professional 4-wheel alignment within 50 miles of repair
• After alignment, verify tire wear patterns are even across the tread and vehicle tracks straight

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