If a Santa Fe 4WD or Tucson 4WD vehicle has an oil leak between the transaxle and transfer case, follow the below repair procedure.
Applicable Vehicles: 2001-’06 (SM) Santa Fe 2.7L and 3.5L 4WD; 2007-’09 (CM) Santa Fe 3.3L 4WD; and 2005-’09 (JM) Tucson 2.7L 4WD
1. Inspect the area of the leakage to determine the source of the leak. If the leaking fluid is:
– ATF (red color, thin oil): Go to Step 2.
– 80W/90 gear oil (brown color, thick oil): Go to Step 11.
ATF Leak from the Transaxle (Red Color, Thin Oil):
2. If ATF is leaking from the transaxle, refer to TSB 02-50-006 and remove the transfer case.
3. Inspect the inner and outer seal for damage using a small flashlight and your finger. See Fig. 1.
– If the inner seal is damaged, replace the transaxle.
– If the outer seal is damaged, go to Step 4.
4. Using a flat screwdriver, carefully pry the outer oil seal from the transaxle. Caution: Be careful not to scratch the case.
5. Install a new seal using the special service tool, P/N 09473-26000-35, and a rubber hammer. See Fig. 2.
6. Inspect the transfer case input shaft for burrs or sharp edges. Remove any burrs with a small file or emory cloth.
7. Pull and push the hollow shaft with a force of 5 lb.-f. to confirm it is secured inside the transfer case. See Fig. 3.
– If not secured, replace the transfer case.
– If OK, go to Step 8.
8. Reinstall the transfer case.
9. Add Hyundai SPIII ATF to bring the ATF level to the “FULL” mark on the dipstick according to TSB 06-40-016.
10. Road-test the vehicle and check for leakage between the transfer case and transaxle. If a red ATF leak is found, replace the transaxle.
Oil Leak from the Transfer Case (Brown Color, Thick Oil):
11. If 80W-90 gear oil is leaking from the transfer case, refer to TSB 02-50-006 and remove the transfer case.
12. Using a flat screwdriver, carefully pry the oil seal from the transfer case. Caution: Be careful not to scratch the case.
13. Install a new seal using the special service tool, P/N 09473-26000-35, and a rubber hammer.
14. Reinstall the transfer case.
15. Road-test and check for leakage between the transfer case and transaxle. If a thick, brown gear oil leak is found, replace the transfer case.
Courtesy of Mitchell 1.