Hyundai Genesis DH Quiz
All-Wheel Drive (AWD) System

Rear Axle Flange Repair Procedures

In this manual: All-Wheel Drive (AWD) System
General Information — 9Engine Mechanical System — 103Engine Electrical System — 54Emission Control System — 23Engine Control System/Fuel System — 127Automatic Transmission System (SBC) — 90All-Wheel Drive (AWD) System — 20Drive Shaft and Axle — 27Suspension System — 41Steering — 19Restraints — 56Brake System — 56Body (Interior and Exterior) — 211Body Electrical System — 279Heating, Ventilation, and Air Conditioning — 55
16steps
~96min
4/5difficulty
0204060801006044N·mlb·ft
Tightening torque found on this page
Done 0 of 16

Removal
Be careful when handling the transfer case. Prevention of ITA (Integrated Transfer Actuator) Damage 1) When transporting the transfer case
  • Be careful when lifting the transfer case with a transport package to ensure the ITA does not collide with another transfer case.
  • Be careful not to damage the ITA by contact with the floor or structure.
2) When assembling the transmission
  • Be careful not to damage the ITA by contact with the transmission, floor or structure.
  1. Remove the transfer case from the vehicle. (Refer to All Wheel Drive (AWD) System - "Transfer Case Assembly")
  2. Loosen the filler plug (A) and drain the oil.
  3. Use snap ring pliers (B) to open and remove the snap ring (A).
  4. Install the puller (A) into the rear axle flange (B).
  5. Remove the flange (C) using the puller, including the gasket (A) and O-ring (B).
  6. Remove the radial oil seal (A) using a flat-tip screwdriver.

Installation

  1. Press in the new radial oil seal (A).
  2. Measure and select the appropriate shim as follows.
    Shim kit (available as assembly only)
    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 (do not retain the housing).
  4. Press in the new flange (A).
  5. Press in the O-ring (A).
  6. Check that the O-ring is correctly seated inside the groove.
  7. Insert the new adjusting shim (A) (Procedure 2). The snap ring groove must be fully visible.
  8. Assemble the snap ring (A).
  9. Fill with oil up to the lower edge of the filler plug hole (of the installed transfer case). Tighten the plug to 60 N·m.

    Oil type: Shell TF0870
    • Replace the gasket before reinstalling the filler plug.
  10. Install the transfer case on the vehicle. (Refer to All Wheel Drive (AWD) System - "Transfer Case Assembly")
    • After installation, start the engine, then check for leaks from the transfer case.

Test yourself

A quick Hyundai Genesis DH quiz: every answer comes with an explanation and a link to the manual page.