Transfer Case problems of the 2002 Hyundai Santa Fe

2002 & 2004 Hyundai Santa Fe transmission case defect: we liked the first so much, we bought a second. . . . No indication of maintenance instructions in owners manual. Regarding transfer case attention or maintenance which violently caused the vehicle to dangerously, abruptly stop - resulting in a dangerous highway safety situation and personal injury. We have the old transfer case - which looks inside, like a tossed salad. We paid for the replacement by western auto - a matter that should have been covered under warranty. Reported in great detail to Hyundai USA, they deny responsibility or warranty coverage in effect at the time problem was noticed. Furthermore, the vehicles were purchased as 'dealer demos,' with low mileage and full manufacturers 100,00 mile, 10 year warranty - unfortunately from a dealer misrepresenting themselves as an authorized Hyundai dealership. 2002 vehicle was inspected by the dealership when problem realized, - during warranty period, but reported no problem. We later discovered a repair / modification kit was issued by Hyundai to correct the problem - purchased at western auto - Hyundai service manager claimed he had no knowledge of the item until we showed it to him in a brand new unopened box. Hyundai did install the modification / repair kit to the second 2004 Santa Fe after we brought it to their attention. All documented by hidden camera video recording. Dangerous and costly situation. Please advise. We seek reimbursement for the repair and towing costs. Thank you for your attention. Harold bayuk.

Hi I went to my Hyundai dealer today for what appeared to be a re-occurring fluid leak on the transfer case seal, front passenger side of the vehicle. I was told this time that the leak was caused by a vent tube located at the transfer case. The technical service bulletin referenced by the service advisor states that the fluid will only appear during very cold temperatures. This seems to be what is happening right now ,with my vehicle. My issue is that in order to stop this fluid leak,the dealer tells me that the transfer case vent tube needs to be replaced with a redesigned unit. I am also told that this new unit will not be replaced under the power train warranty. I asked why not?? if this is a design flaw on Hyundai's part ,Hyundai should recall the affected vehicles and install the new vent tube unit at there cost,not the consumers'. I would like to know why I should have to pay $224. 32 parts and labor to correct an issue that is definitely a design flaw that occurred from Hyundai. Please respond accordingly kenneth john basta.

My 2002 v6 4wheel dr Hyundai Santa Fe while driving on the freeway at 65- 70 mph dropped a drive line, igniting flames to the rear of the car. Lithia of fresno claims it was due to low fluids in the transfer case, thus it overheated and the line snapped off. I had the vehicle serviced 2 weeks prior, the fluids were fine, the transfer case was okay. There was a vague hum in the drive of the car after returning from the mountains the week prior to the incident. Other 2nd opinions believe the auto switch in the Smart system failed and left it stuck in 4wheel dr hence overheating the transfer case. It should be covered under waranty for repairs (120,000 on power train/engine) they denied the waranty coverage, so it's not repaired. Estimate is over $6,000. 00. There should be an indicator light in the car as to what drive it's in, and engineering manufacturer defect and hazzard. Investigate please.