GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2009 🢒 XL-7 AWD 🢒 Transmission 🢒 Transfer Case - Getrag 760 🢒 Transfer Case Assembly Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement.
  3. Remove the propeller shaft. Refer to Propeller Shaft Replacement.
  4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
  5. Remove both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side.

    6. Object Number: 1962376 Size: SH
  6. Remove the transfer case mounting bracket bolts (1, 2, 4).
  7. Remove the transfer case mounting bracket (3).
  8. Support the transaxle with a jackstand.
  9. Remove the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear.

    10. Object Number: 1957209 Size: SH
  10. Remove the bolts (1) securing the transfer case to the transaxle.
  11. Remove the transfer case (2) from the transaxle.

    12. Object Number: 1885484 Size: SH
  12. If replacing the transfer case, complete the following steps.
    13. • Remove the transfer case heat shield bolts (1).
    • Remove the transfer case heat shield (2).

Installation Procedure

    Object Number: 1885484 Size: SH
  1. If the transfer case heat shield was previously removed, complete the following steps.
    2. • Install the transfer case heat shield (2).

    Caution: Refer to Fastener Caution in the Preface section.

    • Install the transfer case heat shield bolts (1) and tighten to 10 N·m (89 lb in).

    Object Number: 1957209 Size: SH
  2. Install the transfer case (2) from the transaxle.
  3. Install the bolts (1) securing the transfer case to the transaxle, and tighten to 50 N·m (37 lb ft).
  4. Install the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear.
  5. Remove the jackstand supporting the transaxle.

    6. Note: Tighten bolts in specified sequential order.


    Object Number: 1962376 Size: SH
  6. Install the transfer case mounting bracket (3).
  7. Install the transfer case mounting bracket bolts (1) and tighten to 23 N·m (17 lb ft).
  8. Install the transfer case mounting bracket bolt (4) and tighten to 50 N·m (37 lb ft).
  9. Install the transfer case mounting bracket bolts (2) and tighten to 50 N·m (37 lb ft).
  10. Install both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side.
  11. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
  12. Install the propeller shaft. Refer to Propeller Shaft Replacement.
  13. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement.
  14. Lower the vehicle.