A/T, Drivetrain - Fluid Leak Between A/T, Transfer Case
Group TRANSAXLENumber 09-AT-015-1
Date: SEPTEMBER, 2009
Model
2001-09 SANTA FE 4WD
2005-09 TUCSON 4WD
Subject
AUTOMATIC TRANSAXLE OIL LEAK BETWEEN TRANSAXLE AND TRANSFER CASE
This TSB replaces TSB 09-AT-015 to correct applicable vehicles.
DESCRIPTION:
If a Santa Fe 4WD or Tucson 4WD vehicle has an oil leak between the transaxle and transfer case, follow the repair procedure shown below.
APPLICABLE VEHICLES:
2001~06 (SM) Santa Fe 2.7L & 3.5L 4WD
2007~09 (CM) Santa Fe 3.3L 4WD
2005~09 (JM) Tucson 2.7L 4WD
PARTS INFORMATION
SERVICE PROCEDURE:
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 a finger.
^ 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.
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 lbf to confirm it is secured inside the transfer case.
^ 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.
WARRANTY INFORMATION: