Transfer Case: Installation

[DIESEL 2.2L]

Installation is in reverse order of removal.
CAUTION: Must use a new O-ring (47354-39300) which is placed between the transaxle and the transfer case.
Remove the filler plug (A).

Fig 1: Identifying Filler Plug
Courtesy of HYUNDAI MOTOR CO.
Refill the specification to the specified quantity.
Specification : API GL-5, SAE 75w/90

Quantity : Approx 0.8L

[GASOLINE 2.7L]

Install the transfer assembly to the transaxle.
NOTE: To install the transfer easily, install it by moving the pinion left and right directions, and slightly rotating the inner drive shaft of transfer assembly.
Install the transfer mounting bolts (4EA).
TORQUE:

62~67 Nm (6.2~6.7 kgf.m, 44.8~48.5 lb-ft)
Install the transfer mounting bracket.
TORQUE:

47~51 Nm (4.7~5.1 kgf.m, 34.0~36.9 lb-ft) - 2EA

24~28 Nm (2.4~2.8 kgf.m, 17.4~20.3 lb-ft) - 2EA
Tighten the exhaust manifold mounting nuts (7EA).
TORQUE:

30~35 Nm (3.0~3.5 kgf.m, 21.7~25.3 lb-ft)
Tighten the heat protector (A) mounting nuts (3EA).
TORQUE:

11.8~14.7 Nm (1.2~1.5 kgf.m, 8.7~10.8 lb-ft)

Fig 2: Identifying Heat Protector
Courtesy of HYUNDAI MOTOR CO.
Tighten the pinion case mounting bolts (6EA).
TORQUE:

37~40 Nm (3.7~4.0 kgf.m, 14.5~21.7 lb-ft)

Fig 3: Identifying Pinion Case Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Refill the transfer oil through the filler plug.
Install the front exhaust pipe assembly (A).

Fig 4: Identifying Front Exhaust Pipe Assembly And Drive Shaft
Courtesy of HYUNDAI MOTOR CO.
Install the drive shaft (RH) to the transfer assembly, lower arm ball joint mounting and steering bar tie rod bail joint.
Lower the vehicle down.
Install the engine side cover (RH) and the wheel and tire (RH).
Install the oxygen sensor connector bracket and connect the oxygen sensor connector (A,B). (Engine room right side).

Fig 5: Identifying Oxygen Sensor Connector Bracket
Courtesy of HYUNDAI MOTOR CO.
Connect the battery negative (-) cable.