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Discussion Starter #1
I'm doing my clutch and couldn't find instructions on how to remove transfer case so I've written them up here in case they come in handy for someone else. I'll post the entire clutch job on here when I'm done.
Santa Fe CM 2.2 CRDI 4×4 AWD 5 speed Manual:
transfer case removal using floor jacks and jack stands.



These instructions assume you will plug things that need plugging from dirt and suspend things that need to be suspended to prevent damage and label all wires, nuts and bolts so you know where they go. Be very careful, always compare bolt lengths when removing; some may be shorter than others.



This is a heavy car, don’t just use a jack, use 3 Tonne jack stands. Handbrake and block the wheels, you do not want this beast dropping on your face.

This job is dirty, frustrating and time consuming. You will be working in a cramped position under a heavy car, which will kill you if it falls. You will be breathing in a lot of dust and manhandling heavy components. Dirt will be falling in your face and you will probably smash your fingers at least twice.


1, remove battery and battery tray

2. remove intercooler

3. put car in neutral then disconnect linkage on top of gearbox

4. remove all wires and connectors from top of gearbox (label with tape and take photos).

5. jack up front of car and put on jack stands

6. remove right front wheel

7. remove right brake pads and caliper

8. remove 2 bolts connecting MacPherson strut to wheel hub (easier than removing lower ball joint)

9. remove right intermediate driveshaft support bracket (two bolts)

10. swivel wheel hub out and sideways and remove axle from hub

11. pull right axle out of transfer-case – pry at end if stuck, do not pull on CV joints

12. under car, mark rear-driveshaft and transfer-case output shaft so that when re-installing, they connect in the same place and remain balanced

13. remove driveshaft to transfer-case output shaft bolts, separate the two and secure driveshaft to one side

14. remove the short exhaust flex section (from below turbo to first under car exhaust box) in order to provide access to transfer-case bolts (I used shock-rust spray and impact wrench).

15. there are 6 bolts holding transfer case to trans axle, you can remove all bolts, the splined shaft will still hold it in place. Using long ratchet socket extensions, remove the lower three bolts and the two upper bolts, which you can see. It is too far away and convoluted to reach the location of the last bolt on the top right to place a socket on by hand. You cannot see the bolt, there is too much stuff in the way. I used a mechanics mirror on a stick and long ratchet extension bars with two wobble extensions to place the socket. You need to use wobble socket extensions to remove this bolt.

16. remove the small aluminium protective sheet, which covers some small diameter pressure piping, located just to the right of the transfer case. It is secured in two places, one 10mm bolt and the other a 10mm nut. This plate needs to be removed so you can shift the transfer case far enough right to clear the splined shaft from the trans axle.

17. Pry the transfer-case apart from the trans axle using a large screwdriver or crowbar.

18. When there is about 1cm gap between it and the trans axle, hold the main part of the transfer-case in your right hand and the tail in your left hand then wiggle it towards yourself (if you turn the rear output shaft it will raise or lower the case). Be prepared, after the splined shaft is free of the trans axle, the case will drop if you are not holding it securely. It is not terribly heavy, about 30Kg but it is is unwieldy. The case is removed forwards and down after the splined shaft is free.
 

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Discussion Starter #2
I just realised, steps 1 through 4 are not necessary for transfer case removal -only clutch. sorry!
 

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Discussion Starter #4
still don't have the gearbox out. I'm building my garage at the same time as doing the car. atm im slating the roof any day it doesnt rain and working on car when it rains. TBH I'm finding this job a bit overwhelming so I'm taking it slow and just stopping when I get annoyed instead of stressing out. There are so many frozen nuts and bolts, its taking a lot longer than it should.
 

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Discussion Starter #7
all done. runs like a charm. but boy am i glad my garage was finished - not a job for outside
 
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