Drivetrain - Transfer Case Service Precautions

Group: TRANSFER CASE

Number: 08-TC-001

Date: DECEMBER, 2008

Model:

2001 - 2006 SANTA FE - 4WD
2005 - 2009 TUCSON - 4WD

Subject: TRANSFER CASE SERVICING PRECAUTIONS

DESCRIPTION:
This bulletin describes the precautions necessary to prevent the differential oil seal from being damaged when servicing the transfer case in Santa Fe (SM) or Tucson (JM) 4WD vehicles.





The Hollow Shaft (A) may slip out as shown if the transfer case is shaken excessively while removing it.

VEHICLES AFFECTED:

^ Model: Santa Fe (SM) 4WD and Tucson (JM) 4WD

1. Applicable vehicle production date range:

- Santa Fe (SM): All
- Tucson (JM):All





^ If the transfer case is installed with the Hollow Shaft slipped out, the transmission case differential oil seal may get damaged as shown (B).

^ Preventive measure

First check if the circlip (C) is securely snapped into the groove (D) on the Hollow Shaft. Then connect the transfer case to the transmission following the steps outlined in the Service Procedure.

Note: You can confirm that the Hollow Shaft is installed correctly by gently pulling on it. If it does not pull out, it is installed correctly.

SERVICE PROCEDURE:

NOTE: If the Hollow Shaft is not securely held by the circlip, follow the steps provided below to correct this condition.

NOTE:: There is no need to replace the transfer case assembly if the Hollow Shaft condition is loose.





1. Check if the Hollow Shaft (E) can be pulled out by hand. If the Hollow Shaft can be pulled out, it is not installed correctly.

2. To correct this condition, follow the steps below.





3. Put the transfer case assembly on a level surface so that the inner driveshaft (F) is facing up.

CAUTION: Be careful not to allow the opposite inner driveshaft to
touch the floor.





4. Roll an 8 1/2" x11" paper (G) around the inner shaft without the Hollow Shaft in place.


5. Push the paper downwards until the circlip is in place over the rolled paper.





6. Insert the Hollow Shaft (H) with a plastic hammer so that the circlip securely snaps into the groove on the hollow shaft.

7. Pull out the rolled paper and discard it.

8. Confirm that the Hollow Shaft is securely held by the circlip by pulling on it.

NOTE: If there is a need to replace either the transmission differential and/or the transfer case oil seals, refer to TSB 06-40-009 for the correct procedure.

Normal warranty applies.