This procedure covers the removal and replacement of the torque converter in a 2016-2024 Hyundai Tucson with the 2.5L I4 gas engine and AWD system, requiring transmission removal from the vehicle.

Warnings

Tools required

Parts

• Torque converter × 1 — Use OEM specification for 8-speed automatic
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter (if applicable) × 1 — Use OEM specification
• Transfer case gasket/seal × 1 — Use OEM specification
• Driveshaft center support bearing (inspect) × 1 — Replace if worn

Fluids

• Hyundai SP-IV-M ATF — 10 qt
• Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and isolate
3. Raise vehicle completely and support on jack stands at all four corners
4. Remove engine splash shields and undercovers
5. Install engine support fixture to support engine weight from above, or use overhead hoist with engine support adapter
6. Allow transmission to cool completely if vehicle was recently driven
7. Mark driveshaft-to-differential and transfer case flanges for installation alignment

Procedure

1. 1

   Drain transmission and transfer case fluids
   Position drain pan under transmission pan. Remove transmission pan bolts in crisscross pattern, starting from one end to allow controlled draining. Once drained, remove pan completely and remove transmission filter if equipped. Drain transfer case fluid by removing drain plug. Inspect pan for metal debris or clutch material indicating additional transmission damage.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
2. 2

   Remove driveshafts and transfer case components
   Remove rear driveshaft by unbolting flange connections at transfer case and rear differential. Support driveshaft and remove center support bearing mounting bolts. Remove front driveshafts from transfer case and hubs using appropriate puller if needed. Mark orientation of all components for reassembly. Disconnect transfer case electrical connectors and vent hoses.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
3. 3

   Disconnect transmission cooler lines and electrical connections
   Disconnect transmission cooler lines at transmission using appropriate line wrench to avoid rounding fittings. Cap or plug all openings immediately to prevent fluid loss and contamination. Disconnect all electrical connectors from transmission including shift position sensor, speed sensors, and solenoid harness. Label all connections for reassembly.
4. 4

   Remove exhaust components and crossmember
   Disconnect exhaust system at front catalytic converter flange and remove or lower exhaust as needed for transmission clearance. Remove transmission crossmember mounting bolts. Support transmission with transmission jack before removing crossmember completely. Ensure transmission is securely positioned on jack with safety chain.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
5. 5

   Separate transfer case from transmission
   Remove transfer case-to-transmission mounting bolts. Carefully separate transfer case from transmission by pulling straight back. Transfer case weighs approximately 40-50 lbs, so support weight appropriately. Remove and retain transfer case gasket or seal for replacement.
   ⚠Support transfer case weight before removing final mounting bolt to prevent dropping.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
6. 6

   Remove starter motor and access flexplate
   Remove starter motor mounting bolts and electrical connections. Set starter aside. This provides access to flexplate and torque converter bolts. Clean area around flexplate inspection cover and remove cover screws to expose torque converter-to-flexplate bolts.
   ℹ️Starter motor is heavy and has electrical connections that must be labeled for correct reinstallation.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
7. 7

   Remove torque converter-to-flexplate bolts
   Rotate crankshaft using 22mm socket on crankshaft pulley bolt to access each torque converter bolt through inspection hole. There are typically 6-8 bolts. Use appropriate size socket and remove all torque converter bolts while supporting transmission weight on jack. Mark flexplate orientation to torque converter if reinstalling same converter.
   ⚠Rotate engine only in normal direction of rotation (clockwise from front). Do not force rotation.
   Torque spec

   Torque Converter Bolts50 Nm (37 lb-ft)
8. 8

   Remove transmission-to-engine mounting bolts
   Remove all transmission bell housing bolts connecting transmission to engine block. There are typically 6-8 bolts of varying lengths. Note location of each bolt length for proper reinstallation. Ensure transmission jack is securely supporting transmission weight and positioned for removal angle.
   ⚠️Transmission weighs approximately 150-180 lbs with torque converter. Ensure jack is rated for weight and transmission is secured with safety chain.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
9. 9

   Separate and lower transmission assembly
   Carefully slide transmission straight back away from engine to disengage input shaft from flexplate pilot. Move slowly and keep transmission level. Once clear of engine, carefully lower transmission on jack. During lowering, hold torque converter in place with one hand to prevent it from sliding out of transmission. Tilt transmission as needed to clear frame and suspension components.
   ⚠️Torque converter is only held in transmission by engagement with pump. It can slide out and fall during removal. Keep one hand on converter or use retention strap.
10. 10

    Remove and inspect torque converter
    With transmission on bench, verify torque converter is fully seated before removal. Pull torque converter straight out of transmission pump housing. Inspect converter hub and pilot for damage, scoring, or wear. Inspect transmission input shaft seals and front pump for damage. Check flexplate for cracks around bolt holes and warping. Inspect ring gear teeth on flexplate for damage.
    ℹ️Torque converter cannot be rebuilt or serviced. If damaged or contaminated, complete replacement is required.
11. 11

    Install new torque converter and verify seating
    Ensure new torque converter is correct application for this 8-speed transmission. Align torque converter with transmission pump and slide into place while rotating slightly. Push converter in until it stops, then continue rotating and pushing until you feel three distinct engagement clicks: first with front pump drive gear, second with turbine shaft splines, third with fully seated position. Measure from transmission mounting face to converter pilot - should be approximately 15-20mm recessed confirming proper seating. Apply small amount of ATF to converter hub seal area.
    ⚠️Torque converter MUST be fully seated in three engagement positions. If not fully seated, transmission will be damaged during installation to engine. Verify depth measurement before proceeding.
12. 12

    Reinstall transmission to engine
    Position transmission on jack and raise into position. Hold torque converter in place while raising. Align transmission to engine dowel pins and slide input shaft into flexplate pilot bearing. Transmission should slide into place with moderate effort. If excessive force is required, torque converter is not properly seated - remove and reseat. Install all transmission-to-engine mounting bolts hand-tight first, then torque in star pattern.
    ⚠️Never use mounting bolts to draw transmission to engine. If transmission does not mate within last 10mm with hand pressure, torque converter is not seated properly.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)
13. 13

    Install torque converter to flexplate
    Rotate crankshaft to align flexplate with torque converter bolt holes. Install all torque converter-to-flexplate bolts hand tight first. Rotate crankshaft to access each bolt through inspection opening. Once all bolts are started, torque each bolt in sequence, rotating crankshaft as needed. Tighten evenly in multiple passes to avoid distortion.
    ⚠Use new bolts if manufacturer specifies torque-to-yield bolts. Verify all bolts are started before tightening any to final torque.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)
14. 14

    Reinstall starter and flexplate cover
    Install flexplate inspection cover and torque cover screws. Reinstall starter motor, connecting electrical connections as labeled during removal. Torque starter mounting bolts and verify electrical connections are secure.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

    Mounting Bolts61 Nm (45 lb-ft)
15. 15

    Reinstall transfer case and remaining components
    Install new transfer case gasket or seal on transmission. Position transfer case to transmission, aligning dowel pins. Install and torque mounting bolts. Reinstall transmission crossmember and torque mounting bolts. Reconnect all electrical connectors, ensuring proper seating and locking tabs engaged. Reinstall cooler lines with new seals if equipped, torque fittings appropriately. Reinstall exhaust system components.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)
16. 16

    Reinstall driveshafts
    Reinstall front axle shafts into transfer case and hubs, ensuring proper seating with circlip engagement. Reinstall rear driveshaft, aligning marks made during removal. Install center support bearing mounting bolts and torque. Install driveshaft flange bolts at transfer case and rear differential, aligning reference marks.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)
17. 17

    Install transmission pan and refill fluids
    Install new transmission filter if equipped. Install new transmission pan gasket and position pan. Install pan bolts and torque in crisscross pattern starting from center working outward. Refill transfer case with specified transfer case fluid to proper level. Using fluid pump, add approximately 4-5 quarts of Hyundai SP-IV-M ATF through transmission dipstick tube or fill port.
    ℹ️Initial fill is less than total capacity. Additional fluid will be added during final filling procedure after starting engine.
    Torque spec

    Pan Bolts16 Nm (12 lb-ft)

Reassembly

1. Reinstall all undercovers and splash shields
2. Remove engine support fixture
3. Reconnect negative battery cable
4. Lower vehicle to ground

Verification

• With engine off, add remaining ATF to bring level to cold full mark (approximately 5-6 additional quarts total)
• Start engine and allow to idle. Shift through all gear positions, pausing 2-3 seconds in each position
• With engine at idle and transmission in Park, check fluid level. Add fluid as needed to reach proper cold level
• Test drive vehicle for 10-15 minutes to bring transmission to operating temperature (160-180°F)
• With vehicle on level ground, engine running, and transmission in Park, check fluid level at operating temperature. Fluid should be between hot range marks on dipstick
• Verify smooth shifts in all gear ranges and no slipping during acceleration
• Check for fluid leaks at pan, cooler lines, transfer case mating surface, and all connection points
• Verify no abnormal noises from transmission or transfer case
• Check for vibrations that could indicate driveshaft imbalance or improper installation
• Scan for diagnostic trouble codes and verify no transmission-related codes are present
• Road test and verify AWD system engagement if equipped with selectable modes

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