Hyundai Santa Fe (TM): Transfer Assembly

Hyundai Santa Fe TM 2019-2023 Service Manual / 4 Wheel Drive (4WD) System / Transfer Assembly

Transfer Fluid. Repair procedures

Inspection

•	Transfer oil should be inspected and refilled every 60,000 km (40,000 mile) / 4 year.

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

2.	Loosen the oil filler plug (A). [Diesel 2.2 TCI] [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

Check the oil level.

•	Oil level must be up to fill the hole, if not, add oil until it runs over.

Install the oil filler plug with new gasket.

Tightening torque :

39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9 - 43.4 lb-ft)

5.	Install the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

Replacement

Change		Capacity	Specification
Normal Use	Severe Use	Filled up to lower filler plug thread level. [ Diesel 2.2TCI] : Filled up to lower filler plug thread 0.5L ± 0.0225L (0.13 U.S gal, 0.52 U.S qt, 0.44 lmp qt) ± (0.01 U.S gal, 0.03 U.S qt, 0.02 lmp qt) [Gasoline 2.5, 3.5 MPI] : 0.65 L (0.17 U.S.gal, 0.69 U.S.qt, 0.57 lmp,qt)	API GL-5, SAE75W/85 Hypoid gear oil (SK HCT-5 75W85 equivalent)
No service required	120,000 km (80,000 miles)

Severe driving conditions

•	Driving in dusty, rough roads

•	Drivng in mountains areas

•	Driving for patrol car, taxi, commercial car or vehicle towing

•	Driving over 170Km/h

* Transfer oil should be replaced if the transfer assembly is fall into the water.

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

2.	Drain the transfer oil after loosening the drain plug (A). [Diesel 2.2 TCI] [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

Install the drain plug with new gasket.

Tightening torque :

39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9 - 43.4 lb-ft)

Refill the transfer specified oil after loosening the filler plug (A).

Specified oil : API GL-5, SAE75W/85 Hypoid gear oil (SK HCT-5 75W85 equivalent)

Capacity : Filled up to lower filler plug thread level.

Diesel 2.2 TCI : 0.5L ± 0.0225L(0.13 U.S gal, 0.52 U.S qt, 0.44 lmp qt) ± (0.01 U.S gal, 0.03 U.S qt, 0.02 lmp qt)

Gasoline 2.5 MPI: 0.65 L (0.17 U.S.gal, 0.69 U.S.qt, 0.57 lmp,qt)

[Diesel 2.2 TCI]

[Gasoline 2.5 MPI]

[Gasoline 3.5 MPI]

Install the filler plug with new gasket.

Tightening torque :

39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9 - 43.4 lb-ft)

6.	Install the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

Front Wheel Transfer Assembly. Repair procedures

Removal

[Diesel 2.2 TCI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

2.	Remove the front driveshaft assembly. [Right side] (Refer to Driveshaft and Axle - "Front Driveshaft")

Remove the front propeller shaft assembly (A) from the transfer assembly.

Tightening torque :

49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb-ft)

Remove the transfer case assembly.

(1)

Loosen the transafer assembly upper mounting bolts (A).

Tightening torque :

60.8 - 65.7 N.m (6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)

(2)

Loosen the lower mounting bolts (A) and then removing the transfer case assembly (B).

Tightening torque :

60.8 - 65.7 N.m (6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)

[Gasoline 2.5 MPI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

2.	Remove the front drive shaft assembly. [Right side] (Refer to Driveshaft and Axle - "Front Driveshaft")

3.	Loosen the bolts and then removing the roll rod assembly (A).

Remove the front propeller shaft assembly (A) from the transfer assembly.

Tightening torque :

49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb-ft)

Remove the transfer case assembly.

(1)

Loosen the transafer assembly upper mounting bolts (A).

Tightening torque :

60.8 - 65.7 N.m (6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)

(2)

Loosen the lower mounting bolts (A) and then removing the transfer case assembly (B).

Tightening torque :

60.8 - 65.7 N.m (6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)

[Gasoline 3.5 MPI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

2.	Remove the front drive shaft assembly. [Right side] (Refer to Driveshaft and Axle - "Front Driveshaft")

3.	Loosen the bolts and then removing the roll rod assembly (A).

4.	Remove the front muffler assembly. (Refer to Engine Mechanical System - "Muffler")

Remove the front propeller shaft assembly (A) from the transfer assembly.

Tightening torque :

49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb-ft)

Remove the transfer case assembly.

(1)

Loosen the transafer assembly upper mounting bolts (A).

Tightening torque :

60.8 - 65.7 N.m (6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)

(2)

Loosen the lower mounting bolts (A) and then removing the transfer case assembly (B).

Tightening torque :

60.8 - 65.7 N.m (6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)

Installation

To install, reverse the removal procedures.

•	Be careful not to damage the O-ring (A). If the O-ring is damaged, replace with a new one.

•

Smear and cover splines (B) with molybdenum type high pressure grease.

GREASE SPL-1 equivalent (MS511-07)

[Diesel 2.2 TCI]

[Gasoline 2.5, 3.5 MPI ]

•	Install the propeller shaft to be near runout marking (Transfer assembly 1ea (A), propeller shaft 1ea (B) each other.

Oil Seal. Repair procedures

Replacement

Transaxle side oil seal [Diesel 2.2 TCI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Front Wheel Transfer Assembly")

2.	Remove the transfer assembly side oil seal (A).

3.	Install the oil seal with a new one by using the special service tools [09473-D3600(A), 09231-H1100(B)].

4.	Remove the special service tools

5.	Install the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Transfer Assembly")

6.	Install the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

Driveshaft side oil seal #1 [Gasoline 2.5 / 3.5 MPI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Front Wheel Transfer Assembly")

2.	Remove the dust cover (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

3.	Remove the oil seal #1 (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

4.	Install the oil seal #1 (A) with a new one by using the special service tools (0K473-P2100, 09231-H1100). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

5.	Remove the special service tools

6.	Install the dust cover (A) with a new one. [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

7.	Install the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Transfer Assembly")

8.	If the transfer oil is leaking, add the transfer with oil. (Refer to All Wheel Drive System - "Transfer Oil")

9.	Install the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

Driveshaft side oil seal #2 [Gasoline 2.5 / 3.5 MPI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Front Wheel Transfer Assembly")

2.	Remove the dust cover (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

3.	Remove the oil seal #2 (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

4.	Install the oil seal #2 (A) with a new one by using the special service tools (0K473-P2200, 09231-H1100). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

5.	Remove the special service tools

6.	Install the dust cover (A) with a new one. [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

7.	Install the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Transfer Assembly")

8.	If the transfer oil is leaking, add the transfer with oil. (Refer to 4 Wheel Drive System - "Transfer Oil")

9.	Install the front driveshaft [RH]. (Refer to Driveshaft and axle - "Front Driveshaft")

Driveshaft side oil seal #3 [Gasoline 2.5 / 3.5 MPI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Front Wheel Transfer Assembly")

2.	Remove the dust cover (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

3.	Remove the oil seal #2 (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

4.	Remove the oil seal #3 (A). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

5.	Install the oil seal #3 (A) with a new one by using the special service tools (0K473-P2300, 09231-H1100). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

6.	Install the oil seal #2 (A) with a new one by using the special service tools (0K473-P2200, 09231-H1100). [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

7.	Remove the special service tools

8.	Install the dust cover (A) with a new one. [Gasoline 2.5 MPI] [Gasoline 3.5 MPI]

9.	Install the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Transfer Assembly")

10.	If the transfer oil is leaking, add the transfer with oil. (Refer to 4 Wheel Drive System - "Transfer Oil")

Transaxle side oil seal [Gasoline 2.5 / 3.5 MPI]

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

2.	Remove the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Front Wheel Transfer Assembly")

3.	Remove the transfer assembly side oil seal (A).

4.	Install the oil seal with a new one by using the special service tools (0K473-P2400, 09231-H1100).

5.	Remove the special service tools

6.	Install the transfer assembly. (Refer to 4 Wheel Drive (4WD) System - "Transfer Assembly")

7.	If the transfer oil is leaking, add the transfer with oil. (Refer to 4 Wheel Drive System - "Transfer Oil")

8.	Install the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")

Special service tools

Special Service Tools Engine Tools (Number and name) Illustration Use Diesel 2.2 TCI Oil seal installer 09473-D3600 Used for installing the transfer case oil seal (Driveshaft side) (Used with the handle) ...

Coupling Assembly

Components and components location Component Location 1. Relif valve 2. Pressure sensor 3. Oil hydraulic motor 4. Coupling assembly Direct Electro Hydraulic Actuator Coupling. Description and operation ...