🔧 Tucson - Outer Tie Rod End Replacement

This repair replaces a worn outer tie rod end, which connects the steering rack to the front wheel knuckle. A bad tie rod end can cause loose steering, clunking, uneven tire wear, or poor alignment.

Assumption: This guide covers one front outer tie rod end. Replace both sides if both are worn.

Difficulty Level: Beginner-Intermediate | Estimated Time: 1-2 hours per side

---

⚠️ Safety & Precautions

• ⚠️ Support your Tucson with jack stands. Never work under a vehicle held only by a jack.
• ⚠️ The tie rod controls steering. Make sure all fasteners are tight before driving.
• ⚠️ Do not hammer directly on the threaded stud. This can damage the part or steering knuckle.
• ⚠️ A wheel alignment is required after this repair to prevent tire wear and steering pull.
• ⚠️ Battery disconnect is not required for this repair.

---

🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 2-ton minimum)
• Jack stands (rated 2-ton minimum)
• Wheel chocks
• 21mm lug nut socket
• Breaker bar 1/2-inch drive
• Ratchet 1/2-inch drive
• 17mm wrench
• 19mm socket
• 19mm wrench
• Adjustable wrench 10-inch
• Tie rod end puller (specialty)
• Torque wrench 1/2-inch drive
• Needle-nose pliers
• Paint marker
• Tape measure
• Penetrating oil
• Wire brush
• Rubber mallet
• Safety glasses
• Mechanic gloves

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front outer tie rod end - Qty: 1 per side
• New cotter pin - Qty: 1 per side
• New castle nut or flange nut - Qty: 1 per side
• Wheel alignment service - Qty: 1

---

📋 Before You Begin

• Park your Tucson on level ground and set the parking brake.
• Place wheel chocks behind the rear wheels.
• Keep the steering wheel straight before starting.
• Spray penetrating oil on the tie rod end nut and jam nut. Let it soak for 5-10 minutes.
• A jam nut is the locking nut on the inner tie rod that keeps the outer tie rod end from turning.
• A cotter pin is a small bent metal pin that prevents the nut from loosening.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Wheel

• Use the 21mm lug nut socket and breaker bar 1/2-inch drive to loosen the front wheel lug nuts about 1/2 turn.
• Do not remove the lug nuts yet.
• Loosen while tire touches ground.

Step 2: Raise and Support the Vehicle

• Use the floor jack (rated 2-ton minimum) to lift the front of your Tucson at the approved front lift point.
• Place jack stands (rated 2-ton minimum) under the front side support points.
• Lower the vehicle gently onto the jack stands.
• Use the floor jack as a light backup support, but do not rely on it alone.

Step 3: Remove the Wheel

• Use the 21mm lug nut socket and ratchet 1/2-inch drive to remove the lug nuts.
• Remove the wheel and place it flat under the rocker area as an extra safety backup.

Step 4: Mark the Tie Rod Position

• Use the wire brush to clean the threads where the outer tie rod end meets the jam nut.
• Use the paint marker to mark the position of the jam nut on the inner tie rod threads.
• Use the tape measure to measure from the jam nut to the center of the tie rod stud. Write this measurement down.
• This helps keep the alignment close enough to drive carefully to an alignment shop.

Step 5: Loosen the Jam Nut

• Use the 19mm wrench on the jam nut.
• Hold the outer tie rod end steady with the 17mm wrench if needed.
• Turn the jam nut loose about 1/4 turn only.
• Do not move it far from your paint mark.
• Small movement protects alignment.

Step 6: Remove the Cotter Pin

• Use the needle-nose pliers to straighten and pull out the cotter pin from the tie rod end stud.
• If the cotter pin breaks, remove all loose pieces with the needle-nose pliers.

Step 7: Remove the Tie Rod End Nut

• Use the 19mm socket and ratchet 1/2-inch drive to remove the tie rod end nut from the steering knuckle.
• If the stud spins, apply downward pressure on the tie rod end by hand while loosening the nut with the 19mm socket.

Step 8: Separate the Tie Rod End from the Knuckle

• Install the tie rod end puller (specialty) over the tie rod stud and steering knuckle.
• A tie rod end puller presses the tapered stud out without damaging the steering knuckle.
• Use the correct wrench or socket included with the tie rod end puller (specialty) to tighten the puller screw until the stud pops loose.
• If needed, tap the side of the steering knuckle lightly with the rubber mallet. Do not strike the threaded stud.

Step 9: Count the Turns During Removal

• Unscrew the outer tie rod end by hand or with the adjustable wrench 10-inch.
• Count every full turn as it comes off the inner tie rod.
• Write down the number of turns.
• This helps install the new tie rod end in the same approximate position.

Step 10: Install the New Tie Rod End

• Thread the new outer tie rod end onto the inner tie rod by hand.
• Use the same number of turns you counted during removal.
• Line it up with your paint mark and the measurement you recorded.
• Use the adjustable wrench 10-inch only if needed. Do not force the threads.

Step 11: Attach the Tie Rod End to the Steering Knuckle

• Insert the new tie rod end stud into the steering knuckle by hand.
• Install the new nut by hand first to avoid cross-threading.
• Use the 19mm socket and torque wrench 1/2-inch drive to tighten the nut.
• Torque to 34-44 Nm (25-32 ft-lbs)
• If using a castle nut, tighten only farther as needed to align the cotter pin hole. Never loosen the nut to align the hole.

Step 12: Install the New Cotter Pin

• Push the new cotter pin through the hole in the tie rod stud.
• Use the needle-nose pliers to bend the cotter pin ends around the nut.
• Make sure the pin cannot slide out.

Step 13: Tighten the Jam Nut

• Hold the outer tie rod end steady with the 17mm wrench.
• Use the 19mm wrench to tighten the jam nut against the new tie rod end.
• Torque to 50-60 Nm (37-44 ft-lbs)

Step 14: Reinstall the Wheel

• Install the wheel by hand.
• Thread all lug nuts by hand first.
• Use the 21mm lug nut socket and ratchet 1/2-inch drive to snug the lug nuts in a star pattern.

Step 15: Lower and Torque the Wheel

• Use the floor jack (rated 2-ton minimum) to lift slightly off the jack stands.
• Remove the jack stands (rated 2-ton minimum).
• Lower your Tucson until the tire touches the ground.
• Use the 21mm lug nut socket and torque wrench 1/2-inch drive to tighten the lug nuts in a star pattern.
• Torque to 107-127 Nm (79-94 ft-lbs)

---

✅ After Repair

• Turn the steering wheel left and right while parked. Listen for rubbing, popping, or binding.
• Drive slowly in a safe area first. Make sure the steering feels normal.
• Schedule a professional front wheel alignment as soon as possible.
• Recheck the lug nut torque after 25-50 miles using the 21mm lug nut socket and torque wrench 1/2-inch drive.
• If the steering wheel is off-center or the vehicle pulls, drive only to the alignment shop.

---

💰 DIY vs Shop Cost

Shop Cost: $220-$420 per side including alignment-related labor

DIY Cost: $35-$95 per outer tie rod end, plus alignment

You Save: $120-$250 by doing the part replacement yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.8-1.3 hours per side.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.