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.