This procedure covers the removal and replacement of the valve body assembly in the automatic transmission of a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, requiring transmission pan removal and internal disassembly.

Warnings

Tools required

Parts

• Valve body assembly (if replacing) × 1 — Use OEM specification
• Transmission oil pan gasket × 1 — Use OEM specification
• Transmission fluid filter × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification
• Valve body solenoid gaskets/seals × 1 — Use OEM specification
• Transmission fluid (SP-IV-M) × 10 — Hyundai/Kia SP-IV-M ATF

Fluids

• Hyundai SP-IV-M ATF — 10 qt

Preparation

1. Park vehicle on level ground and allow transmission to cool completely (minimum 2 hours after operation)
2. Engage parking brake and place wheel chocks behind rear wheels
3. Disconnect negative battery terminal to prevent electrical issues
4. Raise vehicle on jack stands at all four corners to ensure level working position
5. Remove engine under cover/splash shields to access transmission pan
6. Prepare clean workspace with organized containers for bolts and small parts

Procedure

1. 1

   Drain transmission fluid
   Position drain pan beneath transmission. Remove the transmission drain plug and allow fluid to drain completely. This will take 10-15 minutes. Inspect drained fluid for metal particles or burnt smell indicating internal damage. Install new crush washer on drain plug and reinstall drain plug.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Remove transmission oil pan
   Loosen all transmission pan bolts in a criss-cross pattern, working from the outside bolts inward. Remove bolts completely and carefully lower the pan, being aware residual fluid will drain. Clean the pan thoroughly and inspect magnet for metal debris. Remove and discard old gasket material from both pan and transmission housing using gasket scraper.
   ⚠Approximately 1-2 quarts of additional fluid will drain when pan is removed. Ensure drain pan is positioned correctly.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
3. 3

   Remove transmission filter
   Locate the transmission fluid filter mounted to the valve body or transmission case. Remove filter mounting bolts and carefully pull filter straight down to avoid damaging sealing surface. Discard old filter and clean mounting surface thoroughly.
   Torque spec

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

   Disconnect valve body electrical connector
   Locate the internal wire harness connector attached to the valve body. Carefully release the connector lock tab and gently pull connector straight away from valve body. Do not bend or twist the connector. Support the harness to prevent stress on internal wiring.
   ⚠The transmission control module connector pins are extremely delicate. Inspect for bent pins before disconnection.
5. 5

   Remove valve body mounting bolts
   Identify all valve body mounting bolts (typically 15-20 bolts of varying lengths). Take photos or use a bolt organizer diagram as bolt lengths differ by location. Remove bolts in a criss-cross pattern starting from the outer bolts. Keep bolts organized by position as they are not interchangeable.
   ⚠Some bolts may pass through critical fluid passages. Do not mix up bolt positions as incorrect bolt length can cause internal damage.
   Torque spec

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

   Carefully lower valve body assembly
   With all bolts removed, gently wiggle and lower the valve body assembly. Be prepared to catch small check balls, springs, or separator plates that may fall. Lower the valve body straight down to avoid catching on internal components. Place valve body on clean work surface with the solenoid side facing up.
   ⚠️Check balls and springs will fall out if valve body is tilted. Have clean containers ready and account for all components before reassembly.
7. 7

   Inspect and clean mating surfaces
   With valve body removed, inspect the transmission case separator plate and gasket surfaces. Clean all surfaces with transmission-specific cleaner and lint-free rags. Inspect for scoring, cracks, or damage. Check all fluid passages are clear and free of debris. If replacing valve body, transfer any external sensors if required.
   ℹ️This is the ideal time to inspect clutch pack debris in the pan. Excessive material indicates clutch wear requiring further transmission service.
8. 8

   Install new or serviced valve body
   Install new gaskets and seals on valve body as per service manual. Verify all check balls and springs are in correct positions if valve body was disassembled. Carefully align valve body with transmission case, ensuring separator plate (if equipped) is correctly positioned. Guide valve body into position without forcing.
   ⚠Ensure the manual valve correctly engages with the manual lever linkage inside the transmission. Misalignment will prevent gear selection.
9. 9

   Install valve body mounting bolts
   Install all valve body mounting bolts in their correct positions according to your documentation. Start all bolts by hand to ensure proper threading. Tighten bolts in a criss-cross pattern from center outward in multiple passes. Use appropriate torque specification based on bolt size (20 lb-ft for standard mounting bolts, 45 lb-ft for larger critical bolts).
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
10. 10

    Reconnect electrical connector
    Carefully align the transmission control module connector with the valve body solenoid pack. Press connector straight onto valve body until it clicks and locks into place. Verify connector is fully seated and locking tab is engaged. Route harness to prevent pinching during pan installation.
11. 11

    Install new transmission filter
    Install new transmission filter with new seal/gasket. Align filter properly with mounting holes and press into position. Install filter mounting bolts and torque to specification.
    Torque spec

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

    Install transmission oil pan
    Clean pan magnet and install pan with new gasket. Ensure gasket is properly aligned with all bolt holes. Start all pan bolts by hand. Tighten pan bolts in criss-cross pattern from center outward in multiple passes to ensure even gasket compression.
    ⚠Do not overtighten pan bolts as this will distort the pan and cause leaks. Use torque wrench for final tightening.
    Torque spec

    Pan Bolts16 Nm (12 lb-ft)
13. 13

    Refill transmission fluid
    Remove transmission dipstick or fill plug (depending on model year). Using fluid pump and funnel, add approximately 8 quarts of Hyundai SP-IV-M ATF through dipstick tube or fill port. Start engine and shift through all gear ranges with foot on brake, pausing 3 seconds in each gear. Return to Park and check fluid level with engine running at normal operating temperature. Add fluid as needed to reach proper level on dipstick.
    ⚠Only use Hyundai/Kia SP-IV-M ATF. Using incorrect fluid will cause transmission damage and void warranty.
14. 14

    Perform transmission relearn procedure
    With engine running, perform the transmission adaptive learning reset procedure using a compatible scan tool if available. If scan tool is not available, drive vehicle through multiple gentle acceleration cycles in all gears to allow transmission control module to relearn shift points. Avoid aggressive driving for first 50 miles.
    ℹ️Initial shifts may feel harsh or delayed until adaptive values are relearned. This is normal and should improve within 20-30 miles of driving.

Reassembly

1. Reinstall engine splash shields and under covers
2. Reconnect negative battery terminal
3. Lower vehicle from jack stands
4. Verify no fluid leaks around transmission pan after running engine
5. Reset transmission adaptations with scan tool if available for optimal shift quality

Verification

• Start engine and verify no transmission warning lights on instrument cluster
• Check transmission fluid level with engine at operating temperature and verify proper level
• Inspect transmission pan and drain plug for leaks with engine running
• Test drive vehicle and verify smooth shifting through all gear ranges (P, R, N, D, manual modes if equipped)
• Verify proper engagement of AWD system during test drive
• Recheck fluid level after test drive and top off if necessary
• Monitor transmission operation for first 100 miles and recheck fluid level and leaks after break-in period

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