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Home >> Suzuki >> 2006 >> XL-7 Base, RWD, Standard >> Repair and Diagnosis >> Transmission >> Transfer Case >> Repair Instructions >> Transfer Assembly Dismounting and Remounting >> Dismounting
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Transfer Assembly Dismounting and Remounting: Dismounting

  1. Shift transfer to 4H position operating "2WD <--> 4WD" switch.
  2. In engine room
    1. Disconnect negative (-) cable from battery.
    2. Place wood block (1) between intake manifold (2) and dash panel (3) so that it serves as stopper when engine, transmission and transfer unit hangs down as rear mounting member is removed.
    CAUTION: Make sure to use wood block (1) to prevent contact which may occur between the following parts.
    • Dash panel (3) and intake manifold (2)
    • Cooling fan and its shroud
    Fig 1: Identifying Wood Block, Dash Panel And Intake Manifold
    G04722212Courtesy of SUZUKI OF AMERICA CORP.
  3. In cabin
    1. Remove console box.
    2. Remove transmission shift control lever referring to TRANSMISSION SHIFT CONTROL LEVER REMOVAL AND INSTALLATION .
  4. On lift
    1. Drain transfer oil referring to TRANSFER GEAR OIL INSPECTION AND CHANGE .
    2. Remove rear propeller shaft and front propeller shaft referring to PROPELLER SHAFT REMOVAL AND INSTALLATION .
    3. Remove exhaust No. 2 pipe referring to EXHAUST SYSTEM COMPONENTS .
    4. Disconnect speed sensor coupler referring to VEHICLE SPEED SENSOR (VSS) REMOVAL AND INSTALLATION .
    5. Place transmission jack (1) and remove mounting member (2).
    6. Lower transmission jack (1) gradually and check to ensure that wood block serves as stopper between engine and dash panel.
      Fig 2: Placing Transmission Jack Under Mounting Member
      G04722213Courtesy of SUZUKI OF AMERICA CORP.
    7. Pull off breather hose.
  5. In cabin
    1. Remove transfer front case bolt (1).
      Fig 3: Identifying Transfer Front Case Bolt
      G04722214Courtesy of SUZUKI OF AMERICA CORP.
  6. On lift
    1. Remove transfer mounting (engine rear mounting (1)) by removing bolts (2).
      Fig 4: Identifying Engine Rear Mounting And Bolts
      G04722215Courtesy of SUZUKI OF AMERICA CORP.
    2. Apply transmission jack (3) to transfer (2) to support it.
    3. Disconnect each connector of 4WD switch, 4WD low switch and shift fork switch.
    4. Remove transfer front case bolts (1).
    5. With transfer assembly (2) supported with transmission jack (3), slide it rearward and when it is apart from transmission, lower it.
      Fig 5: Identifying Transfer Front Case Bolts, Transmission Jack And Transfer Assembly
      G04722216Courtesy of SUZUKI OF AMERICA CORP.
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