Tucson 2006-2008

Transfer Case Removal & Installation

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2.0L Engine



Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery (-) terminal.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the propeller shaft.
  8.  
  9. Remove the front muffler.
  10.  
  11. Remove the RH driveshaft.
  12.  
  13. Loosen the oil drain plug and drain the fluid.
  14.  
  15. After draining, re-tighten the oil drain plug to: 29-43 ft. lbs. (39-58 Nm).
  16.  
  17. Support the transfer assembly with a jack.
  18.  
  19. Remove the transfer case assembly by loosening the mounting bolts.
  20.  
  21. Remove the 2 transfer bracket mounting bolts together.
  22.  
  23. Remove the transfer case assembly.
  24.  

To install:


NOTE
Ensure that the transaxle is secured properly to the transaxle jack.

  1. Position the transaxle onto a transaxle jack and secure the transaxle to the jack.
  2.  
  3. Install the transaxle into the vehicle.
  4.  
  5. Install the transfer case mounting bolts and tighten to: 45-49 ft. lbs. (61-66 Nm).
  6.  
  7. Fill the transfer case assembly with the proper type and amount of lubricant.
  8.  
  9. Connect the battery negative (-) cable.
  10.  
  11. Check for leaks.
  12.  

2.7L Engine



Specific to:

Hyundai Tucson 2006-2008

The repair of the transfer assembly requires a special skill and furthermore an improper adjustment of the spacers may cause a severe noise and durability issue. The hypoid gear set is manufactured and controlled as a pair. Any replacement of the part is to be done as a pair, hypoid gear shaft assembly 47308-39200 and pinion shaft 47311-39000.

  1. Remove the battery negative (-) cable.
  2.  
  3. Remove the air intake hose and air cleaner cover.
  4.  
  5. Disconnect the oxygen sensor connector left bank and right bank.
  6.  
  7. Remove the wheel and tire (RH).
  8.  
  9. Remove the engine side cover (RH).
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the lower arm ball joint mounting bolts.
  14.  
  15. Remove the lower arm ball joint from the front axle steering knuckle.
  16.  
  17. Remove the steering bar tie rod ball joint from the knuckle.
  18.  
  19. Remove the drive shaft from the transfer case assembly.
  20.  
  21. Remove the front exhaust pipe.
  22.  
  23. Drain the transfer oil through drain plug hole.
  24.  
  25. Remove the pinion case mounting bolts (A).

    Click image to see an enlarged view

    Fig. Remove the pinion case mounting bolts (A)

  26.  
  27. Remove the alternator drive belt using the tensioner and then alternator assembly by loosening the mounting bolts.
  28.  
  29. Remove the alternator wire terminal mounting nut and connector.
  30.  
  31. Remove the heat protector (A) using a hexagonal socket.

    Click image to see an enlarged view

    Fig. Remove the heat protector (A) using a hexagonal socket

  32.  
  33. Remove the 7 exhaust manifold mounting nuts.
  34.  
  35. Remove the transfer mounting bracket (A).

    Click image to see an enlarged view

    Fig. Remove the transfer mounting bracket (A)

  36.  
  37. Remove the 4 transfer mounting bolts.
  38.  
  39. Using a flat head screw driver, carefully remove the transfer case assembly from the transaxle.
  40.  

To install:

  1. Install the transfer case assembly to the transaxle.
    NOTE
    To aid in installation of the transfer case, install it by moving the pinion in left and right directions, and slightly rotating the inner drive shaft of transfer assembly.

  2.  
  3. Install the 4 transfer mounting bolts. Tighten to: 45-49 ft. lbs. (61-66 Nm).
  4.  
  5. Install the transfer mounting bracket. Tighten to:
    1. 2 bolts to: 34-37 ft. lbs. (46-50 Nm).
    2.  
    3. 3 bolts to: 17-20 ft. lbs. (24-28 Nm).
    4.  

  6.  
  7. Tighten the 7 exhaust manifold mounting nuts to: 22-25 ft. lbs. (29-34 Nm).
  8.  
  9. Tighten the 3 heat protector mounting nuts to: 104-130 inch lbs. (12-15 Nm).
  10.  
  11. Install the alternator and wire connectors. Tighten the mounting bolts to: 15-22 ft. lbs. (20-29 Nm).
  12.  
  13. Tighten the 6 pinion case mounting bolts to: 15-22 ft. lbs. (36-39 Nm).
  14.  
  15. Refill the transfer oil through the filler plug.
  16.  
  17. Install the front exhaust pipe.
  18.  
  19. Install the drive shaft (RH) to the transfer assembly.
  20.  
  21. Install the lower arm ball joint mounting and steering bar tie rod ball joint.
  22.  
  23. Lower the vehicle.
  24.  
  25. Install the engine side cover (RH) and the wheel and tire (RH).
  26.  
  27. Connect the oxygen sensor connectors.
  28.  
  29. Install the air intake hose and air cleaner cover and then connect the oxygen sensor connector.
  30.  
  31. Connect the battery negative (-) cable.
  32.  
  33. Check for leaks.
  34.  

 
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