Santa Fe, Vera Cruz 2006-2008

Transaxle Removal & Installation

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2.4L Engine



Specific to:

Hyundai Santa Fe 2006

Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the battery after removing the battery terminal connections.
  6.  
  7. Remove the air duct assembly.
  8.  
  9. Remove the air cleaner assembly by disconnecting the clamp and the ECM connector.
  10.  
  11. Remove the ground cable from the transaxle.
  12.  
  13. Disconnect the vehicle speed sensor and the back lamp switch integrated connector.
  14.  
  15. Remove the control cable assembly by removing the snap pins and clips.
  16.  
  17. Remove the control cable bracket.
  18.  
  19. Using the special tool (09200-38001), support the engine assembly safely.

    Click image to see an enlarged view

    Fig. Using the special tool (09200-38001) to support the engine assembly-2.4L engine

  20.  
  21. Remove the transaxle upper mounting bolts and the starter motor mounting bolts.
  22.  
  23. After removing the bolts, take the transaxle insulator mounting bracket off.
  24.  
  25. Remove the steering joint assembly bolt.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Remove the front wheels and tires.
  30.  
  31. Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut from the front knuckles.
  32.  
  33. Remove the under shield cover.
  34.  
  35. Remove the roll stopper mounting bolts.
  36.  
  37. Disconnect the muffler hanger rubber.
  38.  
  39. Supporting the sub frame (A) with a jack and the Special tool (09624-38000), remove the mounting bolts.

    Click image to see an enlarged view

    Fig. Support the sub frame (A) with a jack and the Special tool (09624-38000) and remove the mounting bolts-2.4L engine

  40.  
  41. Disconnect the halfshafts from the transaxle.
  42.  
  43. Remove the clutch release cylinder assembly.
  44.  
  45. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts.
  46.  
  47. Lowering the jack slowly, remove the transaxle.
  48.  

To install:

  1. Fit the transaxle assembly to the engine assembly.
  2.  
  3. Install the transaxle lower mounting bolts. Tighten to:
    1. Bolts (A): 22-30 ft. lbs. (30-42 Nm).
    2.  
    3. Bolts (B): 31-40 ft. lbs. (43-55 Nm).

      Click image to see an enlarged view

      Fig. Install the transaxle lower mounting bolts-2.4L engine

    4.  

  4.  
  5. Install the clutch release cylinder assembly.
  6.  
  7. Connect the halfshafts to the transaxle.
  8.  
  9. Supporting the sub frame with a jack and the Special tool(09624-38000), install the mounting bolts. Tighten to: 101-118 ft. lbs. (140-160 Nm).
  10.  
  11. Install the muffler hanger rubber.
  12.  
  13. Install the roll stopper bracket bolts. Tighten to: 36-47 ft. lbs. (50-65 Nm).
  14.  
  15. Install the under shield cover.
  16.  
  17. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front knuckles.
  18.  
  19. Install the front wheels and tires.
  20.  
  21. Install the steering joint assembly bolt. Tighten to: 13-18 ft. lbs. (18-25 Nm).
  22.  
  23. Install the transaxle insulator mounting bracket bolts. Tighten to: 43-58 ft. lbs. (60-80 Nm).
  24.  
  25. Remove the special tool (09200-38001).
  26.  
  27. Install the transaxle upper mounting bolts. Tighten to: 43-60 ft. lbs. (60-80 Nm).
  28.  
  29. Install the starter motor mounting bolts. Tighten to: 28-43 ft. lbs. (39-60 Nm).
  30.  
  31. Install the control cable bracket. Tighten to: 11-16 ft. lbs. (15-22 Nm).
  32.  
  33. Connect the vehicle speed sensor and the back lamp switch integrated connector.
  34.  
  35. Install the control cable assembly by installing the clips and pins.
  36.  
  37. Install the ground cable to the transaxle.
  38.  
  39. Install the air cleaner assembly and the ECM connector.
  40.  
  41. Install the air duct assembly.
  42.  
  43. Install the battery and connect the battery terminals.
  44.  
  45. Install the engine cover.
  46.  
  47. Fill the transaxle to the correct level.
  48.  
  49. Start the engine and check for leaks.
  50.  
  51. Check the wheel alignment and adjust as necessary.
  52.  

2.7L Engine



Specific to:

Hyundai Santa Fe 2006-2008

Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the inter-cooler assembly and the engine cover.
  4.  
  5. Remove the battery.
  6.  
  7. Disconnect the AFS connector.
  8.  
  9. Remove the air cleaner hose and loosen the clamp bolt.
  10.  
  11. Remove the air cleaner upper cover by removing the clips.
  12.  
  13. Remove the air cleaner assembly by removing the 2 mounting bolts.
  14.  
  15. Remove the battery tray by removing the 4 mounting bolts.
  16.  
  17. Remove the ground wire from the transaxle case.
  18.  
  19. Disconnect the vehicle speed sensor and the backup lamp switch integrated connector.
  20.  
  21. Remove the control cable assemblies (A) by removing the snap pins (B) and clips (C).

    Click image to see an enlarged view

    Fig. Remove the control cable assemblies (A) by removing the snap pins (B) and clips (C)-2.7L engine

  22.  
  23. Remove the Concentric Slave Cylinder (CSC) tube (A), which is being clamped, by loosening the nut (B).

    Click image to see an enlarged view

    Fig. Remove Concentric Slave Cylinder (CSC) tube (A), which is being clamped, by loosening the nut (B)-2.7L engine

  24.  
  25. Remove the four mounting bolts of upper part of the transaxle.
  26.  
  27. Support the engine and transaxle by using the special tool (09200-38001).

    Click image to see an enlarged view

    Fig. Using the special tool (09200-38001) to support the engine and transaxle-2.7L engine

  28.  
  29. Remove the transaxle insulator bracket by removing the bolts.
  30.  
  31. Remove the front wheels and tires.
  32.  
  33. Lift up the vehicle.
  34.  
  35. Remove the steering column joint bolt.
  36.  
  37. Remove the undercover.
  38.  
  39. Drain power steering oil through the return tube.
  40.  
  41. Disconnect the power steering pressure hose from the power steering oil pump.
  42.  
  43. Drain the transaxle fluid through the drain plug.
  44.  
  45. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle.
  46.  
  47. Remove the roll stopper mounting bolts.
  48.  
  49. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack.
  50.  
  51. Remove the halfshafts from the transaxle.
  52.  
  53. Disconnect the starter motor connector and remove the starter motor.
  54.  
  55. With 4WD, remove the transfer case assembly. Refer to Transfer Case, removal & installation.
  56.  
  57. Remove the mounting bolts of the lower part of the transaxle, and the left side cover.
  58.  
  59. Remove the transaxle assembly while supporting it with a jack.
  60.  

To install:

  1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
  2.  
  3. Tighten the transaxle under mounting bolts to: 47-62 ft. lbs. (65-85 Nm).
  4.  
  5. Install the starter motor and connect the starter motor connector.
  6.  
  7. With 4WD, install the transfer case assembly. Refer to Transfer Case, removal & installation.
  8.  
  9. Install the halfshafts to the transaxle.
  10.  
  11. Install the transaxle insulator and mounting bracket by tightening the bolts to: 44-59 ft. lbs. (60-80 Nm).
  12.  
  13. Install the sub frame and tighten the bolts to: 44-59 ft. lbs. (60-80 Nm).
  14.  
  15. Connect the power steering return hose.
  16.  
  17. Connect the lower arm, the rod end ball joint, and the stabilizer bar control link to the front knuckle.
  18.  
  19. Install the steering column joint bolt.
  20.  
  21. Install the CSC tube by tightening the nut.
  22.  
  23. Refill transaxle oil through the inlet hole and tighten the filler plug to: 22-25 ft. lbs. (30-35 Nm).
  24.  
  25. Install the undercover.
  26.  
  27. Install the front wheels and tires.
  28.  
  29. Install the transaxle mounting bolts and remove the SST (09200-38001) holding the engine and transaxle assembly. Tighten the mounting bolts to: 47-62 ft. lbs. (65-85 Nm).
  30.  
  31. Connect the power steering pressure hose to the power steering oil pump.
  32.  
  33. Install the control cable assemblies by installing the clips and snap pins.
    NOTE
    Do not reuse the control cable clips. Replace with new ones.

  34.  
  35. Install the vehicle speed sensor and the backup lamp integrated connector.
  36.  
  37. Install the ground wire from the transaxle case.
  38.  
  39. Install the battery tray and the 4 mounting bolts.
  40.  
  41. Install the air cleaner assembly by tightening the 2 mounting bolts.
  42.  
  43. Install the air cleaner upper cover.
  44.  
  45. Install the air cleaner hose and tighten the clamp bolt.
  46.  
  47. Connect the AFS connector.
  48.  
  49. Install the battery.
  50.  
  51. Refill the power steering fluid.
  52.  
  53. Install the engine cover and the inter-cooler assembly.
    NOTE
    Bleed any air from the power steering system.

  54.  
  55. Start the engine and check for leaks.
  56.  
  57. Check the wheel alignment and adjust as necessary.
  58.  

3.5L Engine



Specific to:

Hyundai Santa Fe 2006

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Remove the battery and tray.
  6.  
  7. Remove the air cleaner duct.
  8.  
  9. Remove the air cleaner and air flow hose.
  10.  
  11. Disconnect the back-up light connector, Crankshaft Position (CKP) sensor and oil pressure switch connectors.
  12.  
  13. Disconnect the speedometer cable.
  14.  
  15. Remove the clutch release cylinder bolt.
  16.  
  17. Remove the cotter pin from the shift cable at the transaxle.
  18.  
  19. Remove the clip from the shift cable on the transaxle side.
  20.  
  21. Remove the clip from the select cable at the transaxle side.
  22.  
  23. Separate the steering column shaft joint.
  24.  
  25. Separate the power steering pump hose.
  26.  
  27. Separate the hose after removing the clip from the power steering return hose.
  28.  
  29. Remove the upper transaxle bolt.
  30.  
  31. Remove the starter motor.
  32.  
  33. Install an engine support fixture.
  34.  
  35. Remove the front wheels and calipers.
  36.  
  37. Disconnect the tie rod end, wheel speed sensor, and knuckle mounting bolt.
  38.  
  39. Remove the transaxle mounting bracket and insulator.
  40.  
  41. Remove the front roll stopper insulator bolt, upper and lower stopper bolts and the front roll stopper.
  42.  
  43. Remove the rear roll stopper insulator bolt, and stopper bolt and the roll stopper.
  44.  
  45. Remove the drive shaft.
  46.  
  47. Remove the subframe bolts and subframe.
  48.  
  49. Install a transaxle jack.
  50.  
  51. Remove the transaxle lower bolts.
  52.  
  53. Remove the transaxle-to-engine bolts.
  54.  
  55. Remove the manual transaxle.
  56.  

To install:

  1. Installation is the reverse of removal keeping in mind the following steps and torques:
    1. Transaxle case bolts to: 15-20 ft. lbs. (20-27 Nm).
    2.  
    3. Tighten the transaxle mounting bracket bolts to: 43-58 ft. lbs. (60-80 Nm).
    4.  
    5. Transaxle mounting insulator bolt to: 65-80 ft. lbs. (90-110 Nm).
    6.  
    7. Tighten the front roll stopper-to-transaxle bolts to: 43-58 ft. lbs. (60-80 Nm).
    8.  
    9. Tighten the front roll stopper insulator bolt and nut to: 36-47 ft. lbs. (50-65 Nm).
    10.  
    11. Tighten the front roll stopper-to-subframe bolts to: 43-58 ft. lbs. (60-80 Nm).
    12.  
    13. Tighten the rear roll stopper-to-subframe bolts to: 43-58 ft. lbs. (60-80 Nm).
    14.  
    15. Tighten the rear roll stopper-to-transaxle bolt and nut to: 36-47 ft. lbs. (50-65 Nm).
    16.  
    17. Tighten the rear roll stopper insulator bolt and nut to: 36-47 ft. lbs. (50-65 Nm).
    18.  
    19. Tighten the clutch release cylinder retainers to: 11-16 ft. lbs. (15-22 Nm)
    20.  

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Check the wheel alignment and adjust as necessary.
  8.  

 
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