Transfer Case Disassemble. Suzuki XL-7 AWD 2008

For 1990-2009 cars only

Makes 🢒 Suzuki 🢒 2008 🢒 XL-7 AWD 🢒 Transmission/Transaxle 🢒 Transfer Case - Getrag 760 🢒 Transfer Case Disassemble

Table 1:	Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
Table 2:	Intermediate Drive Shaft Removal
Table 3:	Rear Output Shaft Housing Removal
Table 4:	Right Transfer Case, Input and Output Drive Shaft Removal
Table 5:	Rear Output Shaft Housing Disassembly
Table 6:	Intermediate Drive Shaft Disassembly

Callout	Component Name
1	Transfer Case O-Ring Seal
2	Transfer Case Vent Assembly Tip Remove the vent only if damaged or blocked.
3	Transfer Case Bracket Bolts (Qty: 6)
4	Transfer Case Bracket
5	Transfer Case Heat Shield Bolts (Qty: 3)
6	Transfer Case Heat Shield
7	Transfer Case Drain Plug
8	Transfer Case Fill Plug

Callout	Component Name
1	Front Wheel Drive Shaft Shield Tip After removal, discard the shield. It does not need to be installed. Refer to Transfer Case Description and Operation.
2	Front Wheel Drive Retainer
3	Front Wheel Drive Intermediate Shaft Special Tools J 25070 Heat Gun - 500-750F

Callout

Component Name

Front Wheel Drive Shaft Shield

Tip
After removal, discard the shield. It does not need to be installed. Refer to Transfer Case Description and Operation.

Front Wheel Drive Retainer

Front Wheel Drive Intermediate Shaft

J 25070 Heat Gun - 500-750F

Callout	Component Name
1	Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
2	Transfer Case Rear Output Shaft Housing Tip Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal. Special Tools J 25070 Heat Gun - 500-750F
3	Transfer Case Rear Output Shim
4	Transfer Case Rear Output Shaft Housing Seal O-Ring Tip Discard the O-ring after removal.

Callout

Component Name

Transfer Case Half Bolts (Qty: 12)

Transfer Case - Right

Transfer Case Seal

Transfer Case Input Shaft

Transfer Case Rear Output Drive Shaft

Transfer Case Half Locating Pins (Qty: 2)

Tip

•	Remove the pins only if damaged.

•	Inspect the case for similar damage.

Callout	Component Name
1	Transfer Case Rear Output Drive Gear Nut Tip Use a 30 mm socket or J 29873 . Special Tools J-08614-A Pinion Flange Holder and Remover
2	Transfer Case Rear Output Shaft Flange Special Tools DT-48146 Press Support
3	Transfer Case Rear Output Shaft Bearing Assembly Tip Use a press to remove the output shaft from the housing.
4	Transfer Case Rear Output Shaft Bearing Spacer
5	Transfer Case Rear Output Shaft
6	Transfer Case Rear Output Shaft Oil Slinger Tip Remove the slinger only if damaged. Refer to Rear Output Drive Housing Cleaning and Inspection.
7	Transfer Case Rear Output Shaft Seal Tip Discard the seal after removal.

Callout	Component Name
1	Half Shaft Retainer
2	O-Ring
3	Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2)
4	Front Wheel Drive Intermediate Shaft Bearing Assembly Tip Use a press, with the J 22912-B flat side up, in order to remove the bearing assembly. Special Tools J 22912-B Rear Pinion and Axle Bearing Remover