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Home >> Hyundai >> 2007 >> Tucson GLS, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case Assembly >> Transfer Case >> Reassembly

Transfer Case: Reassembly

NOTE:
  1. Clean all parts except the taper roller bearings. Be careful about the direction of seals.
  2. Oil bearings with hypoid gear oil API GL5.
  3. Smear involute splines all covering with high pressure grease "Klueber microlube GNY202".
  4. Measuring temperature: 20°±5°C.
  5. O-ring has to be dipped into hypoid gear oil API GL5. Allow excess oil to drain.
  6. Contact surface of the transfer housing to be coated with "SEALANT 732" or equivalent (silicon type sealing agent) prior to mounting. Coating thickness: 0.1 mm MIN. Prior to coating, mating surfaces must be clean and free from oil and grease.
  7. Transfer oil specification: Hypoid gear oil "API GL5, SAE 80W/90 SHELL SPIRAX AX EQUIVALENT". Filled up to lower filler plug thread level (Approx. 0.8L)
  8. The hypoid gear set must be managed as a pair. Whenever installing or replacing a hypoid gear shaft assembly (47308-39200) or a pinion shaft (47311-39000). Make sure to install or replace as a pair.
  9. In reassembling, refer to the two figures below. See Fig 1 and Fig 2.
    Fig 1: Identifying Manual Transaxle Length
    G04811082Courtesy of HYUNDAI MOTOR CO.
  1. Install the transfer drive gear with the taper roller bearings (47366-39000 and 47465-39000) into transfer housing.
  2. Applying the preload (100 to 200N) to bearings, measure the dimension J. See Fig 1.
    Fig 2: Identifying Transfer Drive Gear With Taper Roller Bearings (47366-39000 And 47465-39000)
    G04811083Courtesy of HYUNDAI MOTOR CO.
  3. Measure the dimension H on transfer cover (47314-39200).
    Fig 3: Identifying Transfer Cover (47314-39200)
    G04811084Courtesy of HYUNDAI MOTOR CO.
  4. Select the spacer thickness from the chart below. Thickness S4= H-J+K. (K: Bearing preload = 0.07 to 0.11 mm.)

    Corresponding preload torque (measured without seals): 120 to 180 Ncm.

    SPACER THICKNESS CHART

    PART NUMBER SPACER THICKNESS (mm)
    47383-39152 1.520-1.539
    47383-39154 1.540-1.559
    47383-39156 1.560-1.579
    47383-39158 1.580-1.599
    47383-39160 1.600-1.619
    47383-39162 1.620-1.639
    47383-39164 1.640-1.659
    47383-39166 1.660-1.679
    47383-39168 1.680-1.699
    47383-39170 1.700-1.719
    47383-39172 1.720-1.739
    47383-39174 1.740-1.759
    47383-39176 1.760-1.779
    47383-39178 1.780-1.779
    47383-39180 1.800-1.819
    47383-39182 1.820-1.839
    47383-39185 1.85-1.88
    47383-39189 1.89-1.92
    47383-39193 1.93-1.96
    47383-39197 1.97-2.00
    47383-39201 2.01-2.04
    47383-39205 2.05-2.08
    47383-39209 2.09-2.12
    47383-39213 2.13-2.16
    47383-39217 2.17-2.20
    47383-39221 2.21-2.24
    47383-39225 2.25-2.28
    47383-39229 2.29-2.32
    47383-39233 2.33-2.36
  5. Reassemble the selected spacer above.
  6. Measure the dimension U and V.

    U.... Finished dimension of transfer housing. 

    V.... Distance from back of the hypoid gear to bearing measured under 100 to 200N preload. 

  7. Select the spacer thickness from the chart below. Thickness S2=U-(V + mounting distance 52.0 mm).
    SPACER THICKNESS CHART

    PART NUMBER SPACER THICKNESS(mm)
    47384-39130 1.300-1.319
    47384-39132 1.320-1.339
    47384-39134 1.340-1.359
    47384-39136 1.360-1.379
    47384-39138 1.380-1.399
    47384-39140 1.400-1.419
    47384-39142 1.420-1.439
    47384-39144 1.440-1.459
    47384-39146 1.460-1.479
    47384-39148 1.480-1.499
    47384-39150 1.500-1.519
    47384-39152 1.520-1.539
    47384-39154 1.540-1.559
    47384-39156 1.560-1.579
    47384-39158 1.580-1.599
    47384-39160 1.600-1.619
    47384-39162 1.620-1.639
    47384-39164 1.640-1.659
    47384-39166 1.660-1.679
    47384-39168 1.680-1.699
    47384-39170 1.700-1.719
    47384-39172 1.720-1.739
    47384-39174 1.740-1.759
    47384-39176 1.760-1.779
    47384-39178 1.780-1.799
    47384-39180 1.800-1.819
    47384-39182 1.820-1.839
    47384-39184 1.840-1.859
    47384-39186 1.860-1.879
    47384-39188 1.880-1.899
    47384-39190 1.900-1.919
    47384-39192 1.920-1.939
    47384-39194 1.940-1.959
    47384-39196 1.960-1.979
    47384-39198 1.980-1.999
    47384-39200 2.000-2.019
    47384-39202 2.020-2.039
    47384-39204 2.040-2.059
    47384-39206 2.060-2.079
    47384-39208 2.080-2.099
    47384-39210 2.100-2.119
    47384-39212 2.120-2.139
    47384-39214 2.140-2.159
    47384-39216 2.160-2.179
    47384-39218 2.180-2.199
    47384-39220 2.200-2.219
    47384-39222 2.220-2.239
    47384-39224 2.240-2.259
    47384-39226 2.260-2.279
    47384-39228 2.280-2.299
    47384-39230 2.300-2.319
    47384-39232 2.320-2.339
    47384-39234 2.34-2.37
    47384-39238 2.38-2.41
    47384-39242 2.42-2.45
    47384-39246 2.46-2.49
    47384-39250 2.50-2.53
  8. Install the spacer selected above, the taper roller bearings and the hypoid gear shaft assembly (47308-39200). And preload the assembly without the spacer (Hypoid gear shaft assembly-Transfer cover side) with 100 to 200N.
  9. Measure the dimension L after 10 rotations.
  10. Measure the dimension M on transfer cover (47314-39200).
  11. Select the spacer thickness from the chart above in the step  7. Thickness S3=M-L+(0.09 to 0.12 mm) preload.
  12. Install the spacer selected above.
  13. Install the taper roller bearing outer races to the transfer housing and cover.
  14. Insert the inner drive shaft assembly into the transfer cover.
  15. Fixing the inner drive shaft assembly with a snap ring (A), insert a new oil seal into the transfer cover.
    Fig 4: Removing Snap Ring From Transfer Cover
    G04811079Courtesy of HYUNDAI MOTOR CO.
  16. Install a new oil seal (A) in the transfer housing.
    Fig 5: Identifying Oil Seal(47452-39000), Transfer Drive Gear Left Hand Side)
    G04811075Courtesy of HYUNDAI MOTOR CO.
  17. Install the hypoid gear shaft assembly (A) in the transfer housing.
    Fig 6: Identifying Hypoid Gear Shaft Assembly From Transfer Housing
    G04811074Courtesy of HYUNDAI MOTOR CO.
  18. Install the transfer drive gear assembly (A) in the transfer housing.
    Fig 7: Identifying Transfer Drive Gear Assembly From Transfer Housing
    G04811073Courtesy of HYUNDAI MOTOR CO.
  19. Assemble the transfer cover (A) and inner drive shaft assembly (B) with the transfer housing assembly. Tighten the mounting bolts.

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

    Fig 8: Identifying Transfer Cover With Inner Drive Shaft
    G04811072Courtesy of HYUNDAI MOTOR CO.
  20. Measure the dimension F.

    F.... Assembled dimension of pinion assembly. 

    G.... Finished dimension of transfer housing. (=88.0 mm) 

    E.... Mounting distance (=69.500 ± deviation). 

  21. Select the spacer thickness from the chart below. Thickness S1=E+F-G
    NOTE: If it is not possible to reach the exact mounting distance, select the next thinner spacer S1.
    SPACER THICKNESS CHART

    PART NUMBER SPACER THICKNESS(mm)
    47385-39125 1.25-1.28
    47385-39129 1.29-1.32
    47385-39133 1.33-1.36
    47385-39137 1.37-1.40
    47385-39141 1.41-1.44
    47385-39145 1.45-1.48
    47385-39149 1.49-1.52
    47385-39153 1.53-1.56
    47385-39157 1.57-1.60
    47385-39161 1.61-1.64
    47385-39165 1.65-1.68
    47385-39169 1.69-1.72
    47385-39172 1.720-1.739
    47385-39174 1.740-1.759
    47385-39176 1.760-1.779
    47385-39178 1.780-1.799
    47385-39180 1.800-1.819
    47385-39182 1.820-1.839
    47385-39184 1.840-1.859
    47385-39186 1.860-1.879
    47385-39188 1.880-1.899
    47385-39190 1.900-1.919
    47385-39192 1.920-1.939
    47385-39194 1.940-1.959
    47385-39196 1.960-1.979
    47385-39198 1.980-1.999
    47385-39200 2.000-2.019
    47385-39202 2.020-2.039
    47385-39204 2.040-2.059
    47385-39206 2.060-2.079
    47385-39208 2.080-2.099
    47385-39210 2.100-2.119
    47385-39213 2.13-2.16
    47385-39217 2.17-2.20
    47385-39221 2.21-2.24
    47385-39225 2.25-2.28
    47385-39229 2.29-2.32
    47385-39233 2.33-2.36
  22. Install the pinion assembly with the selected spacer above and measure the circumference backlash on pinion.

    (Measuring diameter, backlash and permissible deviations for measurement on pinion, see table below). If the result is out of permissible range, change the spacer thickness S2, then start again with the step  8 -  12).

    TIPS FOR SPACER ADJUSTMENT FOR HYPOID GEAR BACKLASH AND CONTACT PATTERN 

    SPACER THICKNESS CHART

    ITEM SYMPTOM REMEDY
    Backlash When more than the standard value (0.16 ~ 0.21mm) Adjust backlash by installing the spacer S1 using a thinner one and gradually install a thicker one.
    When less than the standard value (0.16 ~0.21 mm) Adjust backlash by installing the spacer S1 using a thicker one and gradually install a thinner one.
    SPACER THICKNESS CHART

    ITEM SYMPTOM REMEDY
    Hypoid gear tooth contacy pattern
    G04811090
    • Normal state
    • Standard tooth pattern

      Both drive and coast surfaces are in center in lateral direction and slightly inclines to TOE side in vertical direction

    • If the pattern deviates from the standard, adjust it by following proce dure
    G04811361
    • Abnormal state
    • The dirve surface inclines to TOE and TOP and the coast surface inclines to HEEL and TOP

    The tooth contact patterncan be moved to the arrow direction by installing the spacer S2(47384-39000) using a thinner one and gradually install a thickerone
  23. Remove the pinion assembly. With the spacer S3 and transfer cover mounted, combined preload torque for the hypoid gear shaft assembly and transfer gear (measured on transfer gear) should be 2.7 to 3.8 Nm. The spacer S3 has to be changed, if the preload torque is not within the permissible range.
  24. Tighten the pinion assembly mounting bolts (6EA) to install the pinion assembly (A).

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

    NOTE:
    1. Before installing the pinion assembly, check the pinion O-ring and apply the oil to the O-ring.
    2. To make the installation of the pinion to the transfer easier, tap the pinion using a plastic hammer after aligning the bolt holes.
      Fig 9: Identifying Pinion Assembly
      G04811071Courtesy of HYUNDAI MOTOR CO.
  25. Refill the transfer oil through the drain plug hole to the specification.

    Transfer oil: API GL-5 or SAE 80W/90

    Quantity: 0.8L

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