Repair Procedure
Procedure "A": Leak from the right side axle seal (transfer side)1. Raise the vehicle.
2. Remove the right front wheel.
3. Remove the front wheel speed sensor wire grommet from the bracket.
4. Remove the strut and two bolts and nuts mounting the knuckle.
Tightening torque:
100-120 Nm (1000-1200 kg.cm, 74-88 lb.ft.)
5. Remove the driveshaft from the transfer case inner shaft using a hammer and brass bar.
6. Remove the driveshaft bracket mounting bolts (14 mm: 2 each, 12 mm: 3 each).
Tightening torque:
24-28 Nm (240-280 kg.cm, 17-20 lb.ft)
7. Remove the oil seal and then install the new oil seal (P/N 47350-39010).
8. Reinstall all removed components in the reverse order of removal.
Procedure "B": Gear oil leak between transfer case housing and transmission
1. Drain transfer case oil
2. Remove the transaxle using the procedure outlined in TSB # 02-50-006 or use the appropriate Santa Fe Shop Manual.
3. Remove the old seal; install a new oil seal (P/N 47452-39000).
NOTE:
Oil seal installer, special tool, (P/N 09473-26000) may be used for this operation.
4. Reinstall the transfer case.
5. Replenish the transfer gear oil.
Oil specification:
Use SHELL SPIRAX AX
(SAE 80W/90, API GL-5)
6. Road test and check for oil leak between the transfer case and transmission.
Procedure "C": Leak between pinion case and transfer case housing
1. Raise the vehicle.
2. After marking the companion flange and flange yoke, and the differential companion flange and rubber coupling with a line, remove the propeller shaft.
3. Drain the transfer case oil.
4. Remove the pinion case mounting bolts (12 mm, 5 each) and then remove the pinion case from the transfer case.
Tightening torque:
34-37 Nm (340-370 kg.cm, 25-38 lb.ft)
5. Install the new 0-ring (P/N 47353-39000).
CAUTION:
^ Be sure to use new flange bolts (seal bolts) (P/N 47360-39000) when installing the pinion case sub-assembly to the transfer case.
^ Reuse the removed spacer; otherwise, noise from the hypoid gear may occur.
6. Install the pinion case sub-assembly to the transfer case.
Tightening torque:
34-37 Nm (340-370 kg.cm, 25-38 lb.ft)
7. Remove the oil plug.
8. Add the specified amount and type of oil into the oil hole.
Oil specification:
Use SHELL SPIRAX AX
(SAE 80W/90, API GL-5)
9. Install the oil filler plug.
Procedure "D": Leak at end of pinion case
1. Replace the transfer case assembly.
NOTE:
Drain the transfer case oil before removal.
Procedure "E": Leak between the transfer case cover and housing
1. Drain the transfer case oil.
2. Remove the transaxle using the procedure outlined in TSB # 02-50-006 or use the appropriate Santa Fe Shop Manual.
3. Reseal the transfer case using liquid gasket (P/N 21451-33A01 or equivalent).
NOTE:
Be sure to use new flange bolts (P/N 47356-39000) when reinstalling the transfer case.
Tightening torque:
34 - 37 Nm (340-370 kg.cm, 25-38 lb.ft)
Procedure "F": Leak from the vent tube (air breather plug)
1. For repair procedure, refer to TSB # 02-40-023.
2. To obtain the air breather extension hose (P/N 00473-26000), call your local Hyundai Dealer.