GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2008 🢒 XL-7 FWD 🢒 General Information 🢒 General Information 🢒 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: 1955800 Size: SH
  6. Remove the transfer case mounting bracket bolts (1, 3).
  7. Remove the transfer case mounting bracket (2).

    8. Object Number: 1824986 Size: SH
  8. Remove the transfer case mounting bracket bolts (1, 2).
  9. Remove the transfer case mounting bracket (3).
  10. Remove the transfer case heat shield.
  11. Support the transaxle with a jackstand.
  12. Remove the rear transmission mount and bracket. Refer to Transmission Rear Mount Bracket Replacement .

    13. Object Number: 1824987 Size: SH
  13. Remove the bolts (1) securing the transfer case to the transaxle.
  14. Remove the transfer case (2) from the transaxle.

    15. Object Number: 1962377 Size: SH
  15. If replacing the transfer case, complete the following steps.
    16. • Remove the transfer case heat shield bolts (1).
    • Remove the transfer case heat shield (2).

Installation Procedure

    Object Number: 1962377 Size: SH
  1. If the transfer case heat shield was previously removed, complete the following steps.
    2. • Install the transfer case heat shield (2).
    • Install the transfer case heat shield bolts (1).

    Notice: Refer to Fastener Notice in the Preface section.

    Tighten
    Tighten the bolts to 11 N·m (97 lb in).


    Object Number: 1824987 Size: SH
  2. Install the transfer case (2) from the transaxle.
  3. Install the bolts (1) securing the transfer case to the transaxle.

    4. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  4. Install the rear transmission mount and bracket. Refer to Transmission Rear Mount Bracket Replacement .
  5. Remove the jackstand supporting the transaxle.
  6. Install the transfer case heat shield.

    7. Object Number: 1824986 Size: SH
  7. Install the transfer case mounting bracket (3).
  8. Install the transfer case mounting bracket bolts (1).

    9. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  9. Install the transfer case mounting bracket bolt (2).

    10. Tighten
    Tighten the bolts to 23 N·m (17 lb ft).


    Object Number: 1955800 Size: SH
  10. Install the transfer case mounting bracket (2).
  11. Install the transfer case mounting bracket bolts (1, 3).

    12. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  12. Install both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side .
  13. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
  14. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .
  15. Lower the vehicle.