Technical Service Bulletin

Subject

Group

TRANSAXLE

Number

09-AT-015-1

DateSEPTEMBER, 2009

Mode

l 2001~09 SANTA FE 4WD. 2005~09 TUCSON 4WD

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 4WD2007~09 (CM) Santa Fe 3.3L 4WD2005~09 (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.

MODEL PART NUMBER PART NAME AVAILABLE FROM

2001~06 (SM) Santa Fe 4WD2007~09 (CM) Santa Fe 4WD 2005~09 (JM) Tucson 4WD

47452-39000 Oil seal PDC

09473-26000-35 Oil seal installer SPX: 1-866-539-4248

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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.

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Technical Service Bulletin

Group

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.

TRANSAXLE

Number09-AT-015-1

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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:

MODEL OP CODE OPERATION OP TIME

CAUSAL P/NUMBER

NATURECODE

CAUSECODE

2001~09 Santa Fe 47452R0F Replace oil seal

4.647452-39000 N87 C38

2005~09 Tucson 47355R00 1.9

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