Hyundai ix35 2.0 CRDi — Transfer Case Spline Failure (AWD models)
On AWD models of the ix35 and Sportage, the splines connecting the gearbox to the transfer case completely shear off, leaving the car as Front-Wheel Drive only.
Severity
CriticalDIY Difficulty
Professional Only
Est. Cost
£1500–£2500
OBD Codes
None
Gearbox
Typical layout and location for the Gearbox assembly.
Symptoms
- Sudden clunk or bang from underneath the car
- Complete loss of rear-wheel drive (front wheels spin easily in mud/snow)
- Grinding noise from the transfer case area
Root Cause
Lack of lubrication from the factory on the splined shaft. Moisture gets in, the splines rust, and the torque of the 2.0 diesel engine shears the rusted metal clean off.
How To Fix
- Extremely expensive repair. The transfer case and the differential unit inside the gearbox must be replaced.
- Many owners simply remove the propshaft and drive it as a 2WD car.
- If repairing, the gearbox must be removed and stripped.
- Cost: £1,500 - £2,500
Estimated Repair Costs
| Repair Option | Est. Cost (GBP) |
|---|---|
| DIY (parts only) | £600–£1000 |
| Independent Garage | £1500–£2500 |
| Main Dealership | £2400–£4000 |
Other Faults on This Variant
Air Conditioning Condenser Leak (Stone Damage)
MinorThe air conditioning condenser is mounted at the very front of the cooling pack, making it highly susceptible to stone damage from the road, leading to refrigerant loss.
Front Anti-Roll Bar Drop Link Wear
MinorThe front anti-roll bar drop links wear out on heavily potholed UK roads, causing an annoying knocking sound at low speeds.
Alternator / Smart Charge System Failure
SevereModern vehicles use smart charging systems to reduce engine load, but the complex regulators on the alternators frequently fail.
Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.