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Home >> Hyundai >> 2009 >> Tucson SE, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case Assembly >> Transfer Case >> Installation >> 2.7L 4WD

2.7L 4WD

  1. 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.
  2. Install the transfer mounting bolts (4EA).

    TORQUE: 60.8~65.7 Nm (620~670 kgf.cm, 44.8~48.5 lb-ft)

  3. Install the transfer mounting bracket (A).

    TORQUE: 46.1~50.0 Nm (470~510 kgf.cm, 34.0~36.9 lb-ft) - 2EA

    23.5~27.5 Nm (240~280 kgf.cm, 17.4~20.3 lb-ft) - 3EA

    Fig 1: Identifying Transfer Mounting Bracket
    G04811070Courtesy of HYUNDAI MOTOR CO.
  4. Tighten the exhaust manifold mounting nuts (7EA).

    TORQUE: 29.4~34.3 Nm (300~350 kgf.cm, 21.7~25.3 lb-ft)

  5. Tighten the heat protector (A) mounting nuts (3EA).

    TORQUE: 11.8~14.7 Nm (120~150 kgf.cm, 8.7~10.8 lb-ft)

    Fig 2: Identifying Heat Protector
    G04811069Courtesy of HYUNDAI MOTOR CO.
  6. Connect the alternator wire terminal (A) and connector (B).
    Fig 3: Identifying Alternator Wire Terminal Mounting Nut And Connector
    G04811068Courtesy of HYUNDAI MOTOR CO.
  7. Install the alternator drive belt (A) using the tensioner and then alternator assembly (C) by tightening the mounting bolts (B).

    TORQUE: 19.6~29.4 Nm (200~300 kgf.cm, 14.5~21.7 lb-ft)

    Fig 4: Identifying Alternator Drive Belt, Tensioner And Alternator Assembly
    G04811067Courtesy of HYUNDAI MOTOR CO.
  8. Tighten the pinion case mounting bolts (6EA).

    TORQUE: 36.3~39.2 Nm (370~400 kgf.cm, 14.5~21.7 lb-ft)

  9. Refill the transfer oil through the filler plug.
  10. Install the front exhaust pipe (A).
    Fig 5: Identifying Front Exhaust Pipe
    G04811065Courtesy of HYUNDAI MOTOR CO.
  11. Install the drive shaft (RH) to the transfer assembly, lower arm ball joint mounting and steering bar tie rod ball joint.
  12. Lower the vehicle down.
  13. Install the engine side cover (RH) and the wheel and tire (RH).
  14. Connect the oxygen sensor connector (B) and insert the oxygen sensor connector wire clamp into a bracket. (Engine room right side).
    Fig 6: Identifying Oxygen Sensor Connector - (Engine Room Right Side)
    G04811060Courtesy of HYUNDAI MOTOR CO.
  15. Install the air intake hose and air cleaner cover and then connect the oxygen sensor connector. (A-Engine room left side).
    Fig 7: Identifying Oxygen Sensor Connector - (Engine Room Left Side)
    G04811059Courtesy of HYUNDAI MOTOR CO.
  16. Connect the battery negative (-) cable.
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