This procedure covers removal and installation of a press-in front wheel bearing on a 2016-2024 Hyundai Tucson 2.5L AWD, including hub removal, bearing extraction, and reinstallation.

Warnings

Tools required

Parts

• Front wheel bearing assembly (press-in type) × 1 — Use OEM specification
• Axle nut (new) × 1 — Use OEM specification
• Cotter pin or stake washer × 1 — Verify vehicle specification
• Split pin (lower ball joint) × 1 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is still on ground
3. Loosen but do not remove the axle nut while vehicle is on ground (may require assistant to apply brakes)
4. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove front wheel completely
6. Clean the hub area with wire brush to remove dirt and corrosion

Procedure

1. 1

   Remove axle nut and ABS sensor
   Remove the axle nut completely and set aside (do not reuse). Disconnect the ABS wheel speed sensor electrical connector. Remove the ABS sensor mounting bolt and carefully extract the sensor from the knuckle, taking care not to damage the sensor tip or tone ring.
   Torque spec

   ABS Sensor Bolt11 Nm (8 lb-ft)
2. 2

   Disconnect lower ball joint and tie rod
   Remove the cotter pin and castle nut from the lower ball joint. Use a ball joint separator to disconnect the lower control arm from the knuckle. Remove the tie rod end castle nut and separate the tie rod from the knuckle using a tie rod separator. Support the knuckle assembly to prevent strain on the CV axle.
   ⚠Do not strike the CV axle or allow the knuckle to hang freely, as this can damage the inner CV joint or boot.
3. 3

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and hang the caliper securely using wire or a bungee cord to prevent strain on the brake hose. Remove the brake rotor. If the rotor is seized, use penetrating oil and light tapping with a rubber mallet on the hat section.
   ⚠Never allow the brake caliper to hang by the brake hose. This can damage the hose internally and cause brake failure.
4. 4

   Disconnect strut-to-knuckle mounting
   Remove the two bolts securing the strut assembly to the steering knuckle. Support the knuckle and CV axle assembly as you work. Once bolts are removed, carefully pull the knuckle assembly away from the strut and slide the CV axle out of the hub bore. Remove the entire knuckle assembly from the vehicle.
   ℹ️The CV axle may be tight in the hub. Light tapping with a plastic mallet on the axle end may be necessary while pulling the knuckle away.
5. 5

   Remove hub from knuckle
   Secure the knuckle in a vise with soft jaws, protecting the ABS tone ring. Remove the four hub bolts from the back of the knuckle. Use a hub puller or slide hammer with appropriate adapters to extract the hub from the knuckle. The hub is press-fit and will require significant force. Inspect the hub for wear or damage on the bearing contact surface.
   ⚠Do not strike the hub directly with a hammer or drift, as this will damage the bearing races and contaminate the new bearing.
   Torque spec

   Hub Bolts102 Nm (75 lb-ft)
6. 6

   Remove bearing snap ring and extract bearing
   With the hub removed, locate the snap ring on the inboard side of the knuckle that retains the bearing. Use snap ring pliers to remove this retaining ring. Position the knuckle on a hydraulic press with the outboard side facing down on supports that clear the bearing bore. Use a bearing driver or appropriately sized drift that contacts only the outer bearing race, and press the bearing out from the inboard side. Inspect the bearing bore for damage, scoring, or corrosion.
   ⚠Press only on the outer race when removing the bearing. Pressing on the inner race or balls will damage the bearing and may cause it to explode under pressure.
7. 7

   Clean and inspect knuckle bore
   Thoroughly clean the bearing bore in the knuckle using a wire brush and solvent. Remove all old grease, debris, and corrosion. Inspect the bore for cracks, scoring, or damage. Measure the bore diameter if possible to ensure it is within specification. Check the hub mounting surface for damage. Apply a thin coat of anti-seize compound to the bearing bore.
   ℹ️Any cracks or significant damage to the knuckle bore requires knuckle replacement. A damaged bore will cause premature bearing failure.
8. 8

   Press new bearing into knuckle
   Place the knuckle on the press bed with the outboard side facing up, supported around the bearing bore area. Position the new bearing squarely in the bore with the magnetic encoder ring (if equipped) facing outboard. Use a bearing race driver that contacts only the outer race of the bearing. Apply steady, even pressure to press the bearing fully into the bore until it seats against the shoulder. Do not exceed 10 tons of pressure; if more force is required, verify alignment and bore condition.
   ⚠️Always wear safety glasses when using a hydraulic press. Ensure the bearing is perfectly aligned before applying pressure to prevent cocking and damage.
   ⚠Press only on the outer race. Pressing on the inner race, seal, or magnetic encoder will destroy the new bearing.
9. 9

   Install bearing snap ring
   Once the bearing is fully seated, install the bearing retaining snap ring in the groove on the inboard side of the knuckle. Ensure the snap ring is fully seated in its groove all the way around. Verify the bearing rotates smoothly by hand without excessive resistance or noise.
   ℹ️The bearing should rotate with slight resistance due to internal grease. Grinding or excessive roughness indicates a damaged bearing that must be replaced.
10. 10

    Press hub into new bearing
    Clean the hub mating surface and apply a light coat of anti-seize to the hub outer diameter. Position the knuckle with the outboard side down on the press bed, supporting around the outer edge. Insert the hub from the outboard side. Use a bearing driver or press tool that contacts only the inner race of the bearing (through the hub center). Press the hub into the bearing until fully seated. Measure hub end play; it should be minimal (typically less than 0.05mm).
    ⚠When pressing the hub in, force must be applied through the inner race only. Pressing on the hub flange will damage the bearing.
11. 11

    Install hub bolts
    Clean the hub bolt threads and holes. Apply thread locker to the hub bolt threads as specified by manufacturer. Install the four hub bolts from the back side of the knuckle and torque to specification in a star pattern to ensure even seating.
    ⚠Hub bolts are critical fasteners. Use new bolts if threads are damaged and torque accurately in a star pattern.
    Torque spec

    Hub Bolts102 Nm (75 lb-ft)
12. 12

    Reinstall knuckle assembly to vehicle
    Guide the CV axle shaft through the hub bore while positioning the knuckle assembly. Align the knuckle with the strut mounting holes and install the strut-to-knuckle bolts, tightening snugly but not to final torque yet. Connect the lower ball joint to the knuckle and install the castle nut. Connect the tie rod end and install the castle nut.
    ℹ️Ensure the CV axle splines engage fully into the hub before proceeding. The axle should slide in smoothly.
13. 13

    Install brake components and ABS sensor
    Install the brake rotor onto the hub. Mount the brake caliper and torque the caliper mounting bolts to specification. Clean the ABS sensor tip and bore, then install the ABS sensor into the knuckle. Torque the ABS sensor bolt to specification and reconnect the electrical connector.
    Torque spec

    ABS Sensor Bolt11 Nm (8 lb-ft)
14. 14

    Install new axle nut and final torque
    Install the new axle nut onto the CV axle shaft and torque to specification. Install a new cotter pin through the axle nut castle slots, or stake the nut as per manufacturer specification. Torque all suspension fasteners to their specified values with the vehicle at ride height or wheels on the ground. Install the wheel and torque lug nuts in a star pattern.
    ⚠️The axle nut is a critical safety fastener. Always use a new nut and torque accurately. An improperly torqued axle nut can cause wheel separation.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)
15. 15

    Lower vehicle and perform final checks
    Lower the vehicle to the ground. Verify all fasteners are torqued to specification. Test drive the vehicle at low speed in a safe area, listening for abnormal noises from the wheel bearing area. Check for proper ABS operation by verifying the ABS warning light functions normally.
    ℹ️A new bearing may have slight noise for the first few miles as it seats. However, grinding or groaning indicates improper installation.

Reassembly

1. Torque all suspension and hub fasteners to specification
2. Ensure new axle nut is installed and properly staked or pinned
3. Verify ABS sensor is properly seated and connector is secure
4. Double-check brake caliper mounting and operation before test drive

Verification

• Verify no abnormal noise from the wheel bearing during slow-speed turns in both directions
• Confirm no wheel play by attempting to rock the wheel at 12 and 6 o'clock positions with vehicle raised
• Test ABS function by verifying the ABS warning light extinguishes after engine start and vehicle movement
• Verify no vibration at highway speeds that could indicate hub imbalance or improper installation
• Recheck axle nut torque and cotter pin installation after 50-100 miles of driving

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