This procedure covers the replacement of the outer tie rod end on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including removal, installation, and preparation for wheel alignment.

Warnings

Tools required

Parts

• Outer tie rod end (left or right as needed) × 1 — Use OEM specification
• Cotter pin (3mm x 30mm) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on the side being serviced while vehicle is on ground
4. Raise vehicle using manufacturer-recommended lift points and secure with jack stands
5. Remove wheel completely
6. Spray tie rod end threads and castle nut with penetrating oil if corrosion is present

Procedure

1. 1

   Mark tie rod position for reference
   Before loosening anything, use a white paint marker or grease pencil to mark the position of the outer tie rod end on the inner tie rod threads. Count and record the number of visible threads beyond the lock nut. This provides a reference point to minimize alignment changes during installation.
2. 2

   Remove cotter pin from castle nut
   Locate the cotter pin in the castle nut where the tie rod end connects to the steering knuckle. Use needle-nose pliers to straighten the cotter pin ends, then pull it out completely. Discard the old cotter pin as it cannot be reused.
3. 3

   Loosen tie rod end castle nut
   Using a 19mm socket or wrench, loosen the castle nut on the tie rod end ball stud but do not remove it completely yet. Leave it threaded on a few turns to prevent the tie rod end from suddenly separating and causing injury when using the separator tool.
   ⚠Keep the nut threaded on a few turns to control the separation and prevent sudden release.
4. 4

   Separate tie rod end from steering knuckle
   Insert the tie rod end separator (pickle fork) or ball joint separator between the tie rod end and steering knuckle. Strike the tool with a hammer or use a threaded separator to apply pressure until the ball stud pops free from the knuckle taper. Once separated, remove the castle nut completely.
   ⚠Wear safety glasses when striking separator tools. The ball stud will release suddenly under pressure.
5. 5

   Loosen tie rod lock nut
   Locate the lock nut where the outer tie rod end threads onto the inner tie rod. Using a 22mm wrench, loosen the lock nut but do not remove it completely. This nut locks the outer tie rod end in position and prevents rotation during operation.
6. 6

   Remove outer tie rod end
   While holding the lock nut with one wrench, unthread the outer tie rod end by rotating it counterclockwise off the inner tie rod. Count the number of full rotations required for removal to aid in installation of the new part. Remove the lock nut from the old tie rod end.
7. 7

   Clean inner tie rod threads
   Use a wire brush to clean the threads on the inner tie rod where the outer tie rod end attaches. Remove any dirt, corrosion, or old thread-locking compound. Inspect threads for damage; if threads are damaged, inner tie rod replacement may be necessary.
8. 8

   Install lock nut on new outer tie rod end
   Thread the lock nut onto the new outer tie rod end first, moving it up the threads away from the ball stud end. This ensures it will be in position after the tie rod end is threaded onto the inner tie rod.
9. 9

   Thread new outer tie rod end onto inner tie rod
   Thread the new outer tie rod end clockwise onto the inner tie rod. Use the reference marks and thread count from removal to position it approximately in the same location as the old tie rod end. The adjustment does not need to be perfect but should be close to minimize alignment offset.
10. 10

    Install tie rod end into steering knuckle
    Insert the ball stud of the outer tie rod end into the tapered hole in the steering knuckle. Ensure the stud is fully seated in the taper. Thread the castle nut onto the ball stud by hand, then tighten to specification using a torque wrench.
    Torque spec

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

    Install new cotter pin
    Align the castle nut slots with the hole in the ball stud. If necessary, tighten the castle nut slightly (no more than 1/6 turn additional) to align the slots—never loosen the nut to align. Insert a new cotter pin through the hole and bend the ends around the nut to secure it in place.
    ⚠Never loosen the castle nut to align cotter pin holes. Only tighten within 1/6 turn if needed for alignment.
12. 12

    Tighten tie rod lock nut
    While holding the outer tie rod end with a wrench to prevent it from rotating, tighten the lock nut to specification using a torque wrench. This secures the outer tie rod end position on the inner tie rod. Note that final torque should be verified after professional wheel alignment is completed.
    Torque spec

    Tie Rod Lock Nut68 Nm (50 lb-ft)
13. 13

    Reinstall wheel
    Position the wheel onto the hub and thread lug nuts by hand to prevent cross-threading. Tighten lug nuts in a star pattern to specification using a torque wrench. Lower the vehicle from jack stands and perform final torque verification with the vehicle weight on the ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification before driving
2. Verify cotter pin is properly installed and secured
3. Check that tie rod end boot is not torn or damaged during installation

Verification

• Visually inspect tie rod end connection to steering knuckle to ensure ball stud is fully seated
• Verify cotter pin is properly installed through castle nut and bent to prevent removal
• Confirm all torque specifications have been met
• Test steering operation by turning wheel lock-to-lock while stationary to check for binding
• Schedule wheel alignment immediately—vehicle alignment will be affected by this repair
• After alignment, verify tie rod lock nut is torqued to 68 Nm (50 lb-ft) specification

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