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Home >> Suzuki >> 2009 >> XL7 Limited, AWD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Repair Instructions >> Transfer Case Assembly Replacement >> Removal Procedure
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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. Fig 1: Identifying Transfer Case Mounting Bracket Bolt And Transfer Case Mounting Bracket
    G00491097Courtesy of SUZUKI OF AMERICA CORP.
  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 (FWD) or TRANSMISSION MOUNT BRACKET REPLACEMENT - REAR (AWD) .
    10. Fig 2: Identifying Transfer Case, Transaxle, And Bolts
    G00491098Courtesy of SUZUKI OF AMERICA CORP.
  10. Remove the bolts (1) securing the transfer case to the transaxle.
  11. Remove the transfer case (2) from the transaxle.
    Fig 3: Identifying Transfer Case Heat Shield Bolts And Transfer Case Heat Shield
    G00491099Courtesy of SUZUKI OF AMERICA CORP.
  12. If replacing the transfer case, complete the following steps.
    • Remove the transfer case heat shield bolts (1).
    • Remove the transfer case heat shield (2).
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