Suzuki Vitara, Grand Vitara, XL7 2000-06

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transfer case oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Distributor or Camshaft Position (CMP) sensor, if equipped
     
    Center console
     
    Transmission shift lever and case, if equipped with a manual transmission
     
    Transfer case shift lever
     
    Front and rear driveshafts
     
    Exhaust center pipe
     
    Speedometer cable or Vehicle Speed (VSS) sensor, as equipped
     
    Vent hose
     
    4WD switch connector
     

  6.  
  7. Support the transmission with a jack and remove the transmission mount and crossmember.
  8.  
  9. Place a wooden block at the rear of the cylinder head as shown to support the engine when the transfer case is removed.
  10.  
  11. Lower the transfer case away from the vehicle.
  12.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    4WD switch connector
     
    Vent hose
     
    Speedometer cable or VSS sensor, as equipped
     
    Exhaust center pipe
     
    Front and rear driveshafts. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Transfer case shift lever
     
    Transmission shift lever and case, if equipped with a manual transmission
     
    Center console
     
    Distributor or CMP sensor, if equipped
     
    Negative battery cable
     

  2.  
  3. Fill the transfer case.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transfer case oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Distributor or Camshaft Position (CMP) sensor, if equipped
     
    Center console
     
    Transmission shift lever and case, if equipped with a manual transmission
     
    Transfer case shift lever
     
    Front and rear driveshaft-s
     
    Exhaust center pipe
     
    Speedometer cable or Vehicle Speed (VSS) sensor, as equipped
     
    Vent hose
     
    4WD switch connector
     

  6.  
  7. Support the transmission with a jack and remove the transmission mount and crossmember.
  8.  
  9. Place a wooden block at the rear of the cylinder head as shown to support the engine when the transfer case is removed.
  10.  
  11. Lower the transfer case away from the vehicle.
  12.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    4WD switch connector
     
    Vent hose
     
    Speedometer cable or VSS sensor, as equipped
     
    Exhaust center pipe
     
    Front and rear driveshaft-s. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Transfer case shift lever
     
    Transmission shift lever and case, if equipped with a manual transmission
     
    Center console
     
    Distributor or CMP sensor, if equipped
     
    Negative battery cable
     

  2.  
  3. Fill the transfer case.
  4.  

 
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