This procedure covers the replacement of wheel studs on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, requiring hub removal to press out damaged studs and install new ones.

Warnings

Tools required

Parts

• Wheel stud(s) × 1 — Use OEM Hyundai/Kia wheel stud for correct thread and dimensions
• Axle nut cotter pin or stake nut × 1 — Use OEM specification - verify if vehicle uses cotter pin or staked nut design
• Lower ball joint nut × 1 — Recommended replacement if original is deformed during removal

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind wheels that will remain on ground
3. Loosen wheel lug nuts 1/4 turn while vehicle is still on ground
4. If replacing front studs, remove front wheel center cap and loosen axle nut while vehicle is on ground
5. Raise vehicle with floor jack and support securely on jack stands at manufacturer lift points
6. Remove wheel completely

Procedure

1. 1

   Remove axle nut (front wheels only)
   If working on front wheels, remove the axle nut completely using a breaker bar and appropriate socket. Remove and discard the cotter pin or note if nut is staked type. For rear wheels, skip to step 3.
2. 2

   Disconnect lower ball joint
   Remove the lower ball joint castle nut. Use a ball joint separator or pickle fork to separate the lower control arm from the steering knuckle. Apply pressure with the separator tool while tapping with a hammer until the joint releases. Avoid damaging the ball joint boot.
3. 3

   Support hub assembly and remove mounting bolts
   Support the hub/knuckle assembly with one hand or have an assistant hold it. For front hubs, remove the hub mounting bolts from the back of the knuckle. For rear hubs, remove the hub mounting bolts accessible from behind the brake backing plate. There are typically 4 bolts per hub.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Remove hub assembly
   Carefully pull the hub assembly away from the knuckle. For front hubs, the CV axle will slide out of the hub - support it to prevent damage to the CV boot. For rear hubs, the assembly should pull straight off. Set the hub on a clean work surface with the stud side facing up.
5. 5

   Remove damaged wheel stud
   Using a hydraulic press or large C-clamp, press the damaged wheel stud out from the back of the hub. Position the hub so the stud being removed has clearance to drop through. Apply steady pressure until the stud is completely removed. Clean the stud hole with a wire brush to remove any rust or debris.
   ⚠Ensure the hub is properly supported during pressing to avoid damaging the bearing assembly
6. 6

   Install new wheel stud
   Insert the new wheel stud into the hole from the back side of the hub. The serrated shoulder of the stud should face the back of the hub. Using the hydraulic press or C-clamp, press the stud through until the shoulder is fully seated and flush against the hub mounting surface. You should feel solid contact when fully seated.
7. 7

   Verify stud installation
   Check that the new stud is fully seated with the serrated section tight against the hub. The stud should not rotate by hand. Measure that the stud protrudes the same length as the other studs on the hub. Apply a small amount of anti-seize to the exposed threads if desired.
8. 8

   Reinstall hub assembly
   Position the hub assembly back into the knuckle. For front hubs, carefully guide the CV axle through the hub center bore. Align the mounting bolt holes and insert all mounting bolts hand-tight first, then torque in a crisscross pattern to specification.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Reconnect lower ball joint (front wheels only)
   If working on front suspension, reconnect the lower ball joint to the steering knuckle. Install a new castle nut and torque to specification per service manual. Install new cotter pin or use appropriate locking method.
10. 10

    Install and torque axle nut (front wheels only)
    For front wheels, install a new axle nut and torque to 250 Nm (184 lb-ft). Install a new cotter pin through the axle shaft hole and bend properly, or stake the nut collar into the axle groove if using staked-type nut design.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
11. 11

    Install wheel and torque lug nuts
    Mount the wheel onto the hub, ensuring it seats properly over all studs including the new one. Install all lug nuts hand-tight. Lower vehicle until tire just touches ground to prevent wheel rotation. Torque lug nuts to 140 Nm (103 lb-ft) in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque all fasteners to specification in the sequence described
2. Always use a new axle nut cotter pin or properly stake the nut if applicable
3. Verify the new wheel stud is fully seated and does not rotate
4. Double-check that all mounting bolts are installed and torqued before lowering vehicle

Verification

• Test drive vehicle at low speed and listen for any unusual noises from the wheel area
• After first 50 miles, re-torque wheel lug nuts to 140 Nm (103 lb-ft) to ensure proper seating
• Visually inspect that the new stud is flush with others and properly secured
• Verify no vibration or wobble is present during driving

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