Replace the universal joint (U-joint) on the rear driveshaft of a 2016-2024 Hyundai Tucson 2.5L I4 AWD by removing the driveshaft, pressing out the old U-joint, installing a new one, and reinstalling the driveshaft.

Warnings

Tools required

Parts

• Rear driveshaft U-joint × 1 — Use OEM specification or equivalent
• U-joint strap bolts (if reuse not recommended) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake firmly
2. Place wheel chocks at front wheels
3. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points
4. Ensure adequate working clearance beneath vehicle

Procedure

1. 1

   Mark driveshaft orientation
   Before removing anything, use a marker or paint pen to mark the relationship between the driveshaft yoke and the rear differential pinion flange. Also mark the front slip yoke to the driveshaft tube. These alignment marks are critical for maintaining driveshaft balance and proper phasing during reassembly.
2. 2

   Remove rear driveshaft connection
   Remove the four U-joint strap bolts connecting the rear of the driveshaft to the rear differential pinion flange. Support the driveshaft with one hand while removing the final bolts. The straps and caps will remain on the differential yoke.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Remove driveshaft from vehicle
   Slide the driveshaft rearward to separate the front slip yoke from the transfer case output shaft. Lower the rear of the driveshaft and carefully pull the entire assembly out from under the vehicle. Be prepared for a small amount of fluid drip from the transfer case. Place the driveshaft on a clean workbench.
4. 4

   Remove U-joint snap rings
   Locate the snap rings (circlips) on each of the four bearing cap positions in the yoke. Use snap ring pliers to compress and remove all four snap rings. Some U-joints use internal snap rings while others use external C-clips. Clean the bearing cap bores with a wire brush if necessary.
5. 5

   Press out old U-joint bearing caps
   Place the driveshaft yoke in a U-joint press or use a C-clamp with appropriately sized sockets. Position a smaller socket against one bearing cap and a larger socket on the opposite side to receive the cap. Apply steady pressure to press the bearing cap out. Remove the cap and repeat for the remaining three caps. If the cross becomes loose, remove it from the yoke. Tap stubborn caps gently with a punch if needed.
6. 6

   Clean yoke bearing bores
   Thoroughly clean all four bearing cap bores in the yoke using a wire brush or emery cloth. Remove all rust, corrosion, and old grease. Inspect the bores for damage, scoring, or excessive wear. The bores must be smooth for proper U-joint seating.
7. 7

   Install new U-joint cross
   Remove one bearing cap from the new U-joint (they typically come pre-installed on the cross). Insert the U-joint cross into the yoke so that one trunnion passes through the yoke. If the U-joint has a grease fitting, orient it so the fitting will be accessible after installation. Partially install one bearing cap by hand onto the exposed trunnion.
8. 8

   Press in new bearing caps
   Using the U-joint press or C-clamp, carefully press the first bearing cap into the yoke bore until it is flush enough to install the snap ring. Ensure the cap remains square during installation. Install the snap ring in its groove. Rotate the assembly 180 degrees, install the opposite bearing cap by hand, then press it in until the snap ring groove is exposed. Install the second snap ring. Repeat for the remaining two bearing caps, ensuring all caps are fully seated and all snap rings are properly installed in their grooves.
9. 9

   Verify U-joint operation
   After all snap rings are installed, check that the U-joint rotates freely in all directions without binding. There should be minimal to no play in the joint. If binding occurs, the bearing caps may not be fully seated or debris may be present. If excessive play exists, the snap rings may not be properly seated.
10. 10

    Reinstall driveshaft to transfer case
    Slide the front slip yoke of the driveshaft into the transfer case output shaft, aligning the marks made during disassembly. Ensure the slip yoke is fully engaged. Route the driveshaft to the rear differential.
11. 11

    Connect driveshaft to rear differential
    Align the rear U-joint with the rear differential pinion flange, matching the alignment marks made during disassembly. Install the U-joint straps and bolts. Hand-tighten all four bolts first to ensure proper alignment, then torque the strap bolts evenly in a crossing pattern to specification.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
12. 12

    Check transfer case fluid level
    Inspect the transfer case for fluid level. If significant fluid was lost during driveshaft removal, top off with the correct transfer case fluid to the proper level per manufacturer specifications.

Reassembly

1. Ensure all alignment marks are properly matched to maintain driveshaft balance
2. Verify all U-joint snap rings are fully seated in their grooves
3. Confirm driveshaft rotates freely without binding or vibration when turned by hand
4. Double-check that all U-joint strap bolts are torqued to specification in a crossing pattern

Verification

• Lower vehicle from jack stands and remove wheel chocks
• Start engine and shift through all gear ranges while stationary to verify no abnormal noises
• Test drive vehicle at various speeds (15-45 mph) and listen for vibrations, clunks, or unusual driveline noises
• Verify smooth acceleration and deceleration with no binding or vibration
• Re-torque U-joint strap bolts after 50-100 miles of driving
• If grease fitting is present, lubricate U-joint per manufacturer recommendations

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