This procedure covers the removal and replacement of both outer tie rod ends on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD, requiring a professional wheel alignment upon completion.

Warnings

Tools required

Parts

• Outer tie rod end - driver side × 1 — Use OEM specification
• Outer tie rod end - passenger side × 1 — Use OEM specification
• Cotter pins × 2 — 3mm diameter, appropriate length

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove both front wheels completely
6. Spray tie rod end castle nuts and lock nuts with penetrating oil if corrosion is present

Procedure

1. 1

   Mark and measure existing tie rod position
   Before loosening anything, measure and record the exposed thread length between the tie rod lock nut and the outer tie rod end on both sides. Count the number of exposed threads or use a tape measure from the lock nut to the end of the tie rod end body. Mark the orientation of the tie rod end with paint or a marker. This ensures approximate alignment when installing the new tie rod ends.
2. 2

   Remove driver side cotter pin and castle nut
   Locate the tie rod end castle nut where it connects to the steering knuckle. Use pliers to straighten and remove the cotter pin completely. Discard the old cotter pin. Using a 21mm socket, loosen but do not fully remove the castle nut - leave it threaded on by a few turns to protect the threads and prevent the tie rod from falling when separated.
3. 3

   Separate driver side tie rod end from knuckle
   Position the tie rod end separator tool between the steering knuckle and tie rod end taper. Apply steady pressure with the separator tool while tapping the knuckle boss with a hammer to shock the taper loose. Once the taper releases, remove the castle nut completely and remove the tie rod end from the knuckle. If using a pickle fork, note that it may damage the tie rod end boot (acceptable since you are replacing it).
   ⚠Keep hands clear of the tie rod end separator tool - sudden release can cause injury
4. 4

   Remove driver side tie rod end
   Using a 19mm wrench, loosen the tie rod lock nut that secures the outer tie rod end to the inner tie rod. Once loose, unthread the outer tie rod end by turning it counterclockwise (count the rotations for reference). Remove the lock nut from the inner tie rod threads. Clean the inner tie rod threads with a wire brush.
5. 5

   Install new driver side tie rod end
   Thread the lock nut onto the inner tie rod first, positioning it away from the end. Thread the new outer tie rod end onto the inner tie rod clockwise, using your rotation count or thread measurement from step 1 to position it approximately the same as the original. The tie rod end should thread on smoothly - if resistance is felt, check for cross-threading. Do not tighten the lock nut yet.
6. 6

   Connect driver side tie rod end to knuckle
   Insert the tie rod end stud into the steering knuckle taper. Ensure the stud is fully seated in the taper. Install the castle nut and tighten to specification using a torque wrench. The castle nut slots must align with the stud hole for cotter pin installation. If slots do not align, tighten further (never loosen) to the next slot alignment within acceptable torque range.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
7. 7

   Install driver side cotter pin
   Insert a new cotter pin through the castle nut and tie rod stud hole. Bend the cotter pin ends in opposite directions to secure it - one end can be bent over the top of the nut, the other wrapped around the stud. Ensure the cotter pin cannot back out.
8. 8

   Remove passenger side cotter pin and castle nut
   Repeat the removal process for the passenger side. Straighten and remove the cotter pin with pliers, then loosen the 21mm castle nut but leave it threaded on by a few turns to protect the threads during separation.
9. 9

   Separate passenger side tie rod end from knuckle
   Use the tie rod end separator tool to break the taper connection between the passenger side tie rod end and steering knuckle. Apply steady pressure and tap the knuckle boss to shock the taper loose. Remove the castle nut completely once the taper is released and pull the tie rod end from the knuckle.
10. 10

    Remove passenger side tie rod end
    Loosen the 19mm tie rod lock nut securing the outer tie rod end to the inner tie rod. Unthread the outer tie rod end counterclockwise, counting rotations. Remove the lock nut and clean the inner tie rod threads with a wire brush.
11. 11

    Install new passenger side tie rod end
    Thread the lock nut onto the inner tie rod. Thread the new outer tie rod end onto the inner tie rod clockwise, matching your measurement or rotation count from the original position. Ensure smooth threading without cross-threading. Leave the lock nut loose.
12. 12

    Connect passenger side tie rod end to knuckle
    Insert the tie rod end stud into the steering knuckle taper, ensuring full seating. Install and torque the castle nut to specification. Align the castle nut slots with the stud hole by tightening further if necessary (do not loosen).
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
13. 13

    Install passenger side cotter pin
    Install a new cotter pin through the castle nut and stud hole. Bend the ends in opposite directions to prevent the pin from backing out. Verify the cotter pin is secure.
14. 14

    Reinstall wheels and lower vehicle
    Install both front wheels and thread lug nuts on by hand. Lower the vehicle until the tires just contact the ground (wheels cannot rotate but full weight is not yet applied). Torque the lug nuts in a star pattern to specification. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Do NOT tighten the tie rod lock nuts at this time - they must remain loose until after professional wheel alignment
2. After professional alignment is completed, the technician will torque the tie rod lock nuts to 68 Nm (50 lb-ft)
3. Test drive vehicle at low speed in a safe area to verify steering response before returning to normal operation

Verification

• Verify both cotter pins are properly installed and secured
• Confirm all castle nuts are torqued to specification
• Check that tie rod ends move smoothly through their range of motion without binding
• Ensure wheels lug nuts are torqued properly
• Schedule and complete professional wheel alignment immediately - vehicle is not safe to drive extended distances with preliminary tie rod positioning
• After alignment, verify tie rod lock nuts have been torqued to 68 Nm (50 lb-ft)
• Verify steering wheel is centered when driving straight and vehicle tracks true without pulling

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