Transfer Case: Removal

Remove the battery negative(-) cable.
Remove the air intake hose and air cleaner cover and then disconnect the oxygen sensor and remove the oxygen sensor connector from the oxygen sensor mounting bracket. (engine room left side).

Fig 1: Identifying Oxygen Sensor
Courtesy of HYUNDAI MOTOR CO.
Disconnect the oxygen sensor connector and remove the oxygen sensor connector from the oxygen sensor mounting bracket. (engine room right side).
Remove the oxygen sensor wire mounting bracket.

Fig 2: Identifying Oxygen Sensor Wiring Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove the alternator wire terminal mounting nut.
Remove the wheel and tire (RH).
Lift up the vehicle.
Remove the engine side cover (RH).

Fig 3: Identifying Engine Side Cover (RH)
Courtesy of HYUNDAI MOTOR CO.
Remove the lower arm ball joint mounting bolt.

Fig 4: Identifying Lower Arm
Courtesy of HYUNDAI MOTOR CO.
Remove the lower arm ball joint from the front axle knuckle.

Fig 5: Identifying Lower Arm Ball Joint
Courtesy of HYUNDAI MOTOR CO.
Remove the drive shaft from the transfer.

Fig 6: Identifying Drive Shaft
Courtesy of HYUNDAI MOTOR CO.
Remove the alternator drive belt using the tensioner.

Fig 7: Identifying Alternator, Drive Belt & Tensioner
Courtesy of HYUNDAI MOTOR CO.
Remove the exhaust front pipe.

Fig 8: Identifying Exhaust Front Pipe
Courtesy of HYUNDAI MOTOR CO.
Disconnect the alternator connector.
Remove the alternator mounting bolt and then remove the alternator as shown in the illustration.

Fig 9: Removing Alternator
Courtesy of HYUNDAI MOTOR CO.
Lower the vehicle.
Remove the heat protector 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 10: Identifying Heat Protector
Courtesy of HYUNDAI MOTOR CO.
Remove the exhaust manifold mounting upper center nut (1EA) using a hexagonal socket.
NOTE: To remove the exhaust manifold mounting nut easily, before removing the exhaust manifold mounting nuts (6EA), apply the mounting nuts with "WD-40 stops squeaks".

Fig 11: Identifying Exhaust Manifold
Courtesy of HYUNDAI MOTOR CO.
Lift up the vehicle.
Remove the exhaust manifold mounting nuts (5EA).

Fig 12: Identifying Exhaust Manifold Nuts
Courtesy of HYUNDAI MOTOR CO.
Remove the exhaust manifold as shown in the illustration.

Fig 13: Removing Exhaust Manifold
Courtesy of HYUNDAI MOTOR CO.
Remove the propeller shaft mounting bolts.

Fig 14: Removing Propeller Shaft Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the transfer mounting bracket.

Fig 15: Removing Transfer Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove the transfer mounting bolts (4EA) using the tool as described below illustration.

Fig 16: Removing Transfer Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Using a flathead screw driver, remove the transfer from the transaxle by moving the driver to left and right directions.

Fig 17: Removing The Transfer From Transaxle
Courtesy of HYUNDAI MOTOR CO.
Remove the transfer from the transaxle as shown in the illustration.

Fig 18: Removing Transfer

Courtesy of HYUNDAI MOTOR CO.