This procedure covers removal and replacement of the transmission pan gasket on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD, including fluid drain and refill.

Warnings

Tools required

Parts

• Transmission pan gasket × 1 — Use OEM Hyundai gasket or equivalent
• Transmission drain plug crush washer × 1 — Use OEM specification if equipped

Fluids

• Hyundai SP-IV-M ATF — 5 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine and transmission to cool to ambient temperature (minimum 2 hours after operation)
4. Raise front of vehicle with floor jack and support on jack stands at manufacturer lift points
5. Verify vehicle is stable before working underneath
6. Position drain pan beneath transmission pan

Procedure

1. 1

   Remove transmission splash shield
   Locate and remove the plastic undertray/splash shield beneath the engine and transmission using 10mm socket. This provides access to the transmission pan. Set hardware aside for reinstallation.
2. 2

   Drain transmission fluid via drain plug
   Locate the transmission drain plug on the bottom of the pan. Position drain pan directly beneath plug. Using 12mm socket, slowly loosen drain plug. Remove plug by hand once loose and allow fluid to drain completely (approximately 10-15 minutes). Inspect drain plug threads and sealing surface for damage.
   ⚠Fluid will drain quickly once plug is removed. Keep hands clear of fluid stream to avoid contact.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
3. 3

   Remove transmission pan bolts
   Locate all transmission pan bolts around the perimeter (typically 17-19 bolts). Using 10mm socket, loosen all bolts in a criss-cross pattern, working from center outward. Remove all bolts except two at opposite corners. Carefully loosen remaining bolts while supporting pan by hand.
   ⚠Residual fluid (1-2 quarts) will remain in pan. Have drain pan positioned to catch spillage when pan is lowered.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
4. 4

   Lower and remove transmission pan
   While supporting the pan, remove the final two bolts. Carefully lower the pan, keeping it level to minimize spillage. Pour remaining fluid from pan into drain pan. Inspect interior of pan for metal shavings or debris (small amounts are normal; excessive debris indicates internal wear).
5. 5

   Remove old gasket material
   Using gasket scraper or flathead screwdriver, carefully remove all old gasket material from both the transmission housing mating surface and the pan flange. Take care not to gouge or scratch the aluminum sealing surfaces. Clean both surfaces thoroughly with brake cleaner and lint-free rags until completely free of residue and oil.
   ⚠Do not allow gasket material or debris to fall into the open transmission. Cover opening with clean rag if needed.
6. 6

   Clean transmission pan and inspect filter
   Thoroughly clean the transmission pan interior with brake cleaner. Wipe out all residue with clean rags. Clean the magnet(s) in the pan bottom and inspect for excessive metallic debris. If equipped with a serviceable filter visible from pan opening, inspect for damage (filter replacement requires additional disassembly on this model).
7. 7

   Install new gasket and position pan
   Place new gasket onto the clean transmission pan flange, aligning all bolt holes. Some gaskets are adhesive-backed; others may require careful alignment during installation. Lift pan with gasket into position against transmission housing, ensuring gasket remains properly aligned. Thread in 2-3 bolts finger-tight to hold pan in position.
8. 8

   Install and torque pan bolts
   Install all remaining transmission pan bolts finger-tight. Once all bolts are started, tighten in a criss-cross pattern starting from the center and working outward. Use torque wrench to tighten all bolts to specification in the same criss-cross pattern. Make a second pass to verify all bolts are properly torqued.
   ⚠Over-tightening will distort the pan and cause leaks. Under-tightening will also cause leaks. Use proper torque wrench technique.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
9. 9

   Install drain plug with new washer
   Install new crush washer onto drain plug (if equipped - some models use tapered plug without washer). Thread drain plug into pan by hand until seated, then torque to specification using 12mm socket and torque wrench.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
10. 10

    Reinstall splash shield
    Reposition the plastic splash shield/undertray and secure with original fasteners using 10mm socket. Ensure all clips and bolts are properly seated.
11. 11

    Refill transmission with ATF
    Locate transmission dipstick tube (driver side of engine bay). Insert funnel with long tube into dipstick opening. Add 4.5 quarts of Hyundai SP-IV-M ATF slowly to avoid overfilling. Wait 2-3 minutes for fluid to settle before checking level.
    ⚠Do not overfill transmission. Overfilling causes foaming, overheating, and potential damage.
12. 12

    Check fluid level and adjust
    With engine off and vehicle level, remove dipstick and wipe clean. Reinsert fully, then remove and check level. Fluid should be in the COLD range on dipstick. Add additional fluid in small increments (0.25 qt) if needed to reach proper level. Do not exceed MAX mark.

Reassembly

1. Lower vehicle from jack stands carefully
2. Remove wheel chocks
3. Dispose of used ATF properly at approved recycling facility - do not pour down drains

Verification

• Start engine and allow to idle for 2-3 minutes while monitoring for leaks beneath vehicle
• With engine at idle and parking brake applied, cycle transmission through all gear positions (P-R-N-D-L), pausing 3-5 seconds in each position
• Return to Park and allow engine to reach normal operating temperature (approximately 10 minutes of idling)
• With engine running and fluid at operating temperature, recheck fluid level using HOT range on dipstick - add fluid if needed to reach proper level
• Inspect transmission pan, drain plug, and surrounding areas for any signs of leakage
• Test drive vehicle through all gears and monitor shift quality - shifts should be smooth with no slipping or harshness
• After test drive, perform final leak inspection and fluid level check while engine is hot

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