Hyundai Genesis: Transfer Assembly / Rear Axle Flange Repair procedures

Removal
   
Use caution when handling the transfer case.
Preventing the ITA (Integrated Transfer case Actuator) from damage
1) In case of transporting the transfer case
Use caution when lifting the transfer case from the transporting package to make sure the ITA does not collide with the other transfer case.
Use caution for the ITA not to be impacted from contacting the floor or structure.
2) In case of assembling the transmission
Use caution for the ITA not to be impacted from contacting the transmission, floor or structure.

1.
Remove the transfer case from the vehicle.
(Refer to 4 Wheel Drive (AWD) System-"transfer case assembly")
2.
Release filler plug(A) and oil drain.

3.
Use retaining ring plier(B) to open and remove the retaining ring(A).

4.
Install the gear puller (A) in the rear axle flange (B).

5.
Remove flange (C) with a puller, incl. shim (A) and O-ring(B).

6.
Remove radial seal ring (A) with the screwdriver(-).

Installation
1.
Press in the new radial seal ring (A).

2.
Measure and choose the proper shim as follows.

   
Shim kit (only as a kit available)
2,9 mm M0003830-21
3,5 mm M0003830-15
3,0 mm M0003830-20
3,7 mm M0003830-13
3,1 mm M0003830-19
3,8 mm M0003830-12
3,2 mm M0003830-18
3,9 mm M0003830-11
3,3 mm M0003830-17
4,0 mm M0003830-10
3,4 mm M0003830-16
4,1 mm M0003830

3.
Retain the main shaft (not retain the housing).

4.
Press in the new flange (A).

5.
Press in the O-ring (A).

6.
Check if the O-ring is positioned properly inside the slot.

7.
Put in the new shim (A) (procedure 2), retaining ring groove must be fully visible.

8.
Assemble the retaining ring (A).

9.
Fill the lower edge of the filler plug (installed transfer case) with the oil.
Tighten the plug to 60 Nm (6.0 kgf.m, 44.1 lb-ft).

Oil type: Shell TF0870

   
Replace gasket before reinstalling the filler plug.

10.
Install the transfer case in the vehicle.
(Refer to 4 Wheel Drive (AWD) System - "transfer case assembly")
   
After the installation, start the engine and then check if there are any leakages from the transfer case.
Front Axle Flange Repair procedures
Removal     Use caution when handling the transfer case. Preventing the ITA (Integrated Transfer case Actuator ) from damage 1) In case of transporting the transfer case • ...

O-Ring Radial Repair procedures
Removal     Use caution when handling the transfer case. Preventing the ITA (Integrated Transfer case Actuator) from damage 1) In case of transporting the transfer case • ...

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