Transfer Case: Removal

[GASOLINE 2.7L]

NOTE:

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.
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).

Remove the battery negative (-) cable.
Disconnect the oxygen sensor connector (A,B) and remove the oxygen sensor connector bracket. (Engine room right side).

Fig 1: Identifying Oxygen Sensorh Connector And Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove the wheel and tire (Right side).
Remove the engine side cover (A) (Right side).
Remove the drive shaft (A) from the transfer, (see DRIVESHAFT )
Remove the front exhaust pipe assembly (A).

Fig 2: Identifying Front Exhaust Pipe Assembly And Drive Shaft
Courtesy of HYUNDAI MOTOR CO.
Drain the transfer oil through drain plug hole.
Remove the pinion case mounting bolts (A-4ea).

Fig 3: Identifying Pinion Case Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the heat protector (A) using a hexagonal socket.
NOTE: To remove the heat protector mounting bolt easily, before removing the heat protector mounting bolts (3EA), apply the mounting bolt with "WD-40 stops squeaks".

Fig 4: Identifying Heat Protector
Courtesy of HYUNDAI MOTOR CO.
Lift up the vehicle.
Remove the exhaust manifold mounting nuts (7EA).
NOTE: To remove the exhaust manifold mounting nut easily, before removing the exhaust manifold mounting nuts (7EA), apply the mounting nuts with "WD-40 stops squeaks".
Remove the transfer mounting bracket (A).
Remove the transfer mounting bolts (4EA).
Using a flat head screw driver, remove the transfer from the transaxle by moving the driver to left and right directions.