Transfer Case - Replacement Procedure

Group:
TRANSAXLE

Number:
02-50-006

Date:
04-2002

Model:
Santa Fe 2001-2002

2001-02 SANTA FE TRANSFER CASE REMOVAL PROCEDURE

DESCRIPTION:

The 2001 MY and 2002 MY Santa Fe shop manuals do not provide transfer case removal procedures. This bulletin provides a procedure to remove the transfer case.

PROCEDURE:

1. Record the customers pre-set radio stations.





2. Disconnect the negative battery cable.





3. Disconnect the heated oxygen sensor (HO2S) connector C39 and remove it from the bracket.

4. Remove the exhaust system.

5. Disconnect the propeller shaft at the transfer case connection.





6. Support the propeller shaft with a bungee cord. (Attach bungee cord to stabilizer bar).





7. Remove the front RH wheel.

8. Remove the front RH CV shaft.

9. Loosen the generator belt and then remove the generator.





10. Remove the lower oxygen sensor.





11. Remove the exhaust manifold heat protector and then remove the exhaust manifold.





12. Remove the transfer case bracket assembly.





13. Disconnect the transfer case by removing all bolts attaching the transaxle housing.

14. Remove the transfer case.





CAUTIONS:
1. Do NOT loosen the frame bolts to gain more clearance.





2. Do NOT separate the rack and pinion assembly from the steering column shaft assembly to gain more clearance.

3. Do NOT mix grade 10 and grade 7 bolts (they may look alike).





4. Do NOT mix bolt lengths (some bolts have only a slight length difference as shown).

1. Install all parts in the reverse order of removal.





2. Torque all bolts using the torque specification provided in the table shown and appropriate shop manuals.

WARRANTY INFORMATION:

Normal warranty procedures apply.