This procedure covers the removal and replacement of the rear upper control arm on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Rear upper control arm × 1 — Use OEM specification
• Upper ball joint nut × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
4. Raise rear of vehicle with floor jack and support securely on jack stands under manufacturer-specified lift points
5. Remove rear wheel completely
6. Spray all control arm fasteners with penetrating oil and allow to soak if vehicle is exposed to salt or corrosion

Procedure

1. 1

   Support the rear knuckle assembly
   Position a floor jack under the rear knuckle/hub assembly with a block of wood to protect components. Raise jack slightly to take tension off the upper control arm but do not lift the vehicle off the jack stands. This prevents the suspension from dropping when the control arm is disconnected.
2. 2

   Remove the upper ball joint nut
   Locate the upper ball joint where it connects to the rear knuckle. Remove the ball joint nut completely using a socket and breaker bar. Note the orientation of the ball joint stud for reassembly.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Separate the ball joint from the knuckle
   Use a ball joint separator tool or pickle fork to separate the upper ball joint from the rear knuckle. Strike the separator tool firmly with a hammer if needed. Once separated, remove the tool and lower the jack slightly to create clearance.
   ⚠The ball joint may release suddenly. Keep fingers clear of pinch points between control arm and knuckle.
4. 4

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the subframe or chassis. This is typically the inboard forward position. Use a socket and breaker bar to remove the bolt completely. Note the bolt orientation and any washers or spacers for reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove the rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the subframe or chassis. This is typically the inboard rearward position. Remove this bolt completely. The control arm should now be free to remove from the vehicle.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove the upper control arm
   Pull the upper control arm away from the mounting points and maneuver it out of the wheel well. Inspect the mounting points on the chassis for damage or excessive rust. Clean the mounting surfaces with a wire brush if needed.
7. 7

   Install the new upper control arm
   Position the new upper control arm into the mounting brackets. Insert the front and rear mounting bolts through the control arm bushings and chassis brackets. Thread bolts by hand but do NOT torque at this time - bolts must be torqued with vehicle weight on wheels.
   ℹ️Control arm bolts are installed finger-tight only at this stage. Final torque occurs after vehicle is lowered.
8. 8

   Connect the ball joint to the knuckle
   Raise the floor jack under the knuckle to align the ball joint stud with the hole in the knuckle. Insert the ball joint stud into the knuckle and thread on the NEW ball joint nut. Torque the ball joint nut to specification immediately.
   ⚠Always replace the ball joint nut with a new one. Do not reuse the old nut as it is a critical safety component.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Reinstall the wheel
   Position the wheel onto the hub and thread all lug nuts by hand. Tighten lug nuts in a star pattern until snug but do not torque to final specification yet.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
10. 10

    Lower vehicle to load suspension
    Carefully remove jack stands and lower the vehicle until the full weight is on all four wheels. Do not lower completely to the ground yet - keep the jack supporting the vehicle at normal ride height. This loads the suspension bushings in their normal operating position.
11. 11

    Torque control arm mounting bolts
    With the vehicle weight on the wheels at normal ride height, torque both the front and rear control arm mounting bolts to specification. This is critical for proper bushing alignment and longevity.
    ⚠Control arm bolts MUST be torqued with vehicle weight on suspension. Torquing while suspended will preload bushings incorrectly and cause premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

    Final wheel installation
    Lower the vehicle completely to the ground. Torque all wheel lug nuts to specification in a star pattern. Remove wheel chocks.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification, particularly the control arm bolts which must be torqued with vehicle weight on wheels
2. Verify the ball joint nut is properly seated and torqued
3. Double-check that no tools or parts were left in the wheel well

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the rear suspension
• Check for proper wheel alignment - vehicle may pull or have uneven tire wear if alignment is off
• Schedule a professional wheel alignment after control arm replacement to ensure proper tire wear and handling
• Re-check torque on all fasteners after 50-100 miles of driving

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