This procedure covers the removal and replacement of the transfer case on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including disconnection of driveshafts and axles.

Warnings

Tools required

Parts

• Transfer case output seal × 1 — Use OEM specification
• Transfer case input seal × 1 — Use OEM specification
• Transfer case gasket/sealant × 1 — Use OEM specification
• Drain plug washer × 1 — Use OEM specification
• Fill plug washer × 1 — Use OEM specification

Fluids

• Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Raise vehicle and support securely on jack stands at manufacturer-recommended lift points.
3. Remove front and rear splash shields/underbody covers to access transfer case and driveshafts.
4. Allow transfer case and surrounding components to cool if vehicle was recently operated.

Procedure

1. 1

   Drain transfer case fluid
   Position drain pan under transfer case. Remove the drain plug from bottom of transfer case and allow fluid to drain completely. Inspect drained fluid for metal particles or unusual debris which may indicate internal damage. Remove fill plug to improve drainage. Reinstall drain plug with new washer after draining.
2. 2

   Mark and disconnect rear driveshaft
   Use paint or marker to mark the relationship between rear driveshaft flange and transfer case output flange for proper reassembly alignment. Remove the flange bolts securing rear driveshaft to transfer case. Support driveshaft and carefully lower it away from transfer case. Secure driveshaft to exhaust or suspension with wire to prevent damage.
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
3. 3

   Mark and disconnect front driveshaft
   Mark the relationship between front driveshaft and front differential/PTU output flange. Remove the flange bolts and carefully separate the front driveshaft. Support and secure the driveshaft away from work area. Some models may have a two-piece front driveshaft requiring additional support at center bearing.
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
4. 4

   Disconnect electrical connectors
   Locate and disconnect the AWD coupler electrical connector on the transfer case. This connector controls the electromagnetic clutch pack. Press the release tab and carefully pull connector straight off to avoid pin damage. Secure connector away from work area.
5. 5

   Disconnect vent hose
   Locate the transfer case vent hose on top of the unit. Carefully pull the vent hose from the transfer case fitting. The hose may be stiff from heat cycling. Note routing for reinstallation.
6. 6

   Support transfer case
   Position transmission jack or equivalent support device under the transfer case. Adjust height to just contact the transfer case and provide support without lifting. The transfer case must be supported before removing mounting bolts to prevent it from falling.
   ⚠️Ensure transfer case is properly supported before removing mounting bolts. The unit can fall suddenly causing injury or damage.
7. 7

   Remove transfer case mounting bolts
   Locate all transfer case mounting bolts securing the unit to the transmission. There are typically 5-7 bolts depending on configuration. Remove the mounting bolts in a crisscross pattern to prevent binding. Keep bolts organized for reinstallation.
   Torque spec

   Transfer Case Bolts35 Nm (26 lb-ft)
8. 8

   Separate and remove transfer case
   With transfer case supported on jack, carefully slide the transfer case rearward to disengage the input shaft from the transmission output shaft. Work slowly and keep unit level to avoid binding. Once separated, lower the transfer case on the jack and remove from under vehicle. The input shaft extends into the transmission and must be pulled straight back.
   ⚠Do not allow transfer case to hang on input shaft as this can damage internal transmission components or the transfer case input seal.
9. 9

   Inspect and prepare mating surfaces
   Inspect the transfer case mounting surface on transmission for damage or debris. Clean all gasket material from transmission mating surface using appropriate gasket scraper. Inspect transfer case input shaft seal and output shaft seals. Replace seals if removing old transfer case. Check transmission output shaft for scoring or damage.
10. 10

    Install transfer case to transmission
    Position replacement or serviced transfer case on transmission jack and raise into position. Apply thin coat of clean transfer case fluid to input shaft splines. Carefully align input shaft with transmission output shaft and slide transfer case forward while keeping it level. Ensure proper engagement before installing bolts. Transfer case should seat flush against transmission mounting surface.
11. 11

    Install and torque mounting bolts
    Install all transfer case mounting bolts and hand tighten. Tighten bolts in a crisscross pattern to ensure even seating. Torque all mounting bolts to specification using a calibrated torque wrench. Verify transfer case is fully seated against transmission before final torquing.
    Torque spec

    Transfer Case Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect electrical and vent connections
    Reconnect the AWD coupler electrical connector to the transfer case, ensuring it clicks into place. Reinstall the vent hose to the transfer case fitting following original routing. Ensure vent hose is not kinked or restricted.
13. 13

    Reinstall driveshafts
    Position front driveshaft and align marks made during disassembly. Install flange bolts and torque to specification. Apply thread locker if specified. Repeat process for rear driveshaft, ensuring alignment marks match. Torque all driveshaft flange bolts properly to prevent vibration.
    Torque spec

    Driveshaft Flange Bolts20 Nm (15 lb-ft)
14. 14

    Fill transfer case with fluid
    Using fluid pump or funnel with extension hose, add 2.5 quarts of transfer case fluid through fill plug opening. Fill until fluid begins to drip from fill hole, indicating proper level. Install fill plug with new washer and tighten securely but do not overtighten. Verify drain plug is properly installed and torqued.
15. 15

    Reinstall underbody covers and lower vehicle
    Reinstall all splash shields and underbody covers removed during disassembly. Ensure all fasteners are properly secured. Remove jack stands and carefully lower vehicle to ground. Remove wheel chocks.

Reassembly

1. Double-check all fasteners are torqued to specification, particularly transfer case mounting bolts and driveshaft flange bolts.
2. Verify all electrical connectors are fully seated and secured.
3. Confirm transfer case fluid level is correct and both drain and fill plugs are installed with new washers.
4. Ensure driveshafts are properly aligned according to marks made during disassembly.

Verification

• Start engine and verify no unusual noises from transfer case area. Listen for grinding or whining that could indicate improper installation.
• Test AWD system engagement by checking for power to rear wheels during test drive. Monitor AWD indicator light on dashboard for proper operation.
• Drive vehicle and verify no driveline vibration at various speeds. Vibration may indicate driveshaft misalignment.
• After initial test drive (10-20 miles), recheck transfer case for leaks around seals and mounting surface.
• Verify transfer case fluid level after test drive by removing fill plug and checking for proper level at fill hole.

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