This procedure addresses replacement of torsion bar components on the 2016-2024 Hyundai Tucson 2.5L AWD. Note: This generation Tucson uses a coil spring suspension system and does not utilize traditional torsion bars.

Warnings

Tools required

Parts

• Stabilizer bar (sway bar) × 1 — Use OEM specification
• Stabilizer bar bushings × 2 — Use OEM specification
• Stabilizer bar link assemblies × 2 — Use OEM specification
• Mounting bracket hardware × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Lift front of vehicle and secure on jack stands at manufacturer lift points
5. Remove both front wheels completely
6. Spray all suspension fasteners with penetrating lubricant and allow to soak

Procedure

1. 1

   Remove stabilizer bar link assemblies
   Locate the stabilizer bar links connecting the sway bar to the strut assemblies. Use an Allen key to hold the link shaft from rotating while removing the upper nut with a socket. Remove both left and right stabilizer bar link upper nuts. Then remove the lower nuts connecting links to the stabilizer bar itself.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Disconnect stabilizer bar from subframe
   Locate the stabilizer bar mounting brackets on the front subframe. There are typically two brackets with two bolts each securing the bar to the subframe. Remove all mounting bracket bolts while supporting the stabilizer bar with one hand to prevent it from falling.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
3. 3

   Remove stabilizer bar assembly
   Carefully maneuver the stabilizer bar out from the subframe area. Note the routing and orientation of the bar for reinstallation. The bar may need to be rotated or angled to clear suspension components and steering linkage during removal.
   ⚠Stabilizer bar is heavy and awkward. Use care to avoid damaging brake lines, ABS sensors, or CV boots during removal.
4. 4

   Inspect and replace bushings
   Remove the old bushings from the stabilizer bar and mounting brackets. Clean the bar contact surfaces with a wire brush. Inspect the bar for cracks, severe corrosion, or damage. Install new bushings onto the stabilizer bar, ensuring the split in the bushing faces the correct direction per manufacturer specifications.
   ℹ️Do not use petroleum-based lubricants on rubber bushings. Use soapy water or silicone spray if lubrication is needed for installation.
5. 5

   Install stabilizer bar to subframe
   Position the stabilizer bar back into the subframe area, routing it through the proper locations. Align the bushings with the mounting bracket locations. Install the mounting brackets and bolts, but do not fully torque at this time. Ensure equal overhang on both sides of the vehicle and that bushings are properly seated.
6. 6

   Connect stabilizer bar links
   Attach the stabilizer bar links to both the stabilizer bar and the strut assemblies. Install the nuts on both upper and lower connections. Use an Allen key to hold the link shaft while threading nuts. Do not fully torque at this time.
7. 7

   Torque mounting bracket bolts
   Using a calibrated torque wrench, torque the stabilizer bar mounting bracket bolts to specification. Work in a cross pattern if multiple bolts per bracket to ensure even clamping force on the bushings.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Torque stabilizer bar link nuts
   Torque all stabilizer bar link nuts to specification. Hold the link shaft with an Allen key to prevent rotation while torquing. Torque both upper nuts (to struts) and lower nuts (to stabilizer bar) on both left and right sides.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
9. 9

   Reinstall wheels and lower vehicle
   Install both front wheels and thread lug nuts by hand. Lower the vehicle until wheels just contact the ground but vehicle weight is not fully transferred. Torque wheel lug nuts in a star pattern to specification. Fully lower vehicle and remove jack stands.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify no tools or parts were left in the wheel well or under vehicle
3. Double-check that all stabilizer bar link nuts are properly secured with Allen key access

Verification

• Test drive vehicle at low speed and verify no clunking or rattling noises from front suspension
• Perform figure-8 turns in empty parking lot to verify stabilizer bar function and proper handling
• Visually inspect all connections after test drive to ensure no loosening has occurred
• Check for proper wheel alignment if steering pull is noticed

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