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

- Queenstown, MD, USA

I bought a 2002 Hyundai Santa Fe, standard 5-speed. Since that time I have had to replace the clutch twice. Now I am replacing it again as it was damaged by the fly wheel. A new fly wheel costs $1500. I have made extensive efforts to find a used one. Most of the salvage yards tell me that they don't have one because it is a frequent problem and everyone is looking for one. My mechanic tells me most fly wheels are mounted to the engine and don't have this problem. Also most fly wheels cost under $100, so most warranties do not cover the fly wheel. It seems this is a manufacturing problems since it happens frequently.

- El Paso, TX, USA