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Transfer: NVH Suzuki XL7 I

Transfer Case 8 illustrations ~469 words

Intermittent Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to TRANSFER CASE FLUID REPLACEMENT .
Loose propeller shaft mounting boltsTighten the bolts, as required. Refer to FASTENER TIGHTENING SPECIFICATIONS - PROPELLER SHAFT .
Loose torque tube bracket or a damaged bracket bushingTighten the bracket bolts or replace the bracket, as required.
Incorrect gear oilReplace the gear oil. Refer to SEALERS, ADHESIVES, AND LUBRICANTS .

CAUSES - INTERMITTENT NOISE

Constant Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to TRANSFER CASE FLUID REPLACEMENT .
Low gear oil levelsFaulty oil seals or other type of external leaks may contribute to lower than required fluid levels. Refer to TRANSFER CASE LEAK DIAGNOSIS . Fill to proper level with gear oil. Refer to SEALERS, ADHESIVES, AND LUBRICANTS .
Worn propeller shaft constant velocity jointsReplace the propeller shaft assembly. Refer to PROPELLER SHAFT REPLACEMENT .
Worn bearing in the rear differential torque tube assemblyReplace the torque tube assembly.
Bearing noise within the transfer case A grinding or roar type noise will increase or decrease relative to the vehicle speed.Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required.
Gear set whine noise within the transfer case A whine type noise will increase or decrease relative to the vehicle speed.Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required. Contributing factors may include: Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

CAUSES - CONSTANT NOISE

CauseCorrection
Drain and fill the unit with new oil with ultraviolet dye J 28431-6 before using the J 28428-E black light, when inspecting for leaks.
Restricted or damaged ventilation assemblyReplace the ventilation assembly, as required.
Worn, scored, or missing drain and/or fill plug sealing washersInstall new drain plugs and tighten the plugs per specifications.
Worn or damaged input or output shaft oil sealReplace the output shaft oil seal, as required.
Cut or damaged output housing O-ring sealReplace the O-ring seal, as required.
Worn internal shaft oil seals Worn or damaged internal shaft oil seals may be detected by a fluid leak at the vent hole area on the bottom of the cover.Replace the oil seals, as required.
Worn or damaged right side axle shaft oil sealReplace the axle shaft oil seal and axle shaft, as required.
Cut or damaged transaxle assembly-to-transfer case O-ring sealsReplace the O-ring seals, as required.
Cases or housings porosity or leaking seal surfacesReplace the transfer case assembly if it cannot be repaired.

CAUSES - TRANSFER CASE LEAK DIAGNOSIS

Scheme 33

Scheme 33: Removal Procedure
Scheme 33: Removal Procedure
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
  2. Remove the drain plug (2).
  3. Remove the fill plug (1).

Scheme 34

Scheme 34: Installation Procedure
Scheme 34: Installation Procedure
  1. Clean the drain plug. CAUTION: Refer to «COMPONENT FASTENER TIGHTENING NOTICE»(ref-268407-S22652339512007102300000) .
  2. Install the drain plug (2). Tightening torque Tighten the drain plug to 39 N.m (29 lb ft).
  3. Fill the transfer case with synthetic gear lubricant GM P/N 89021677 (Canadian P/N 89021678) to the bottom of the fill plug, or 540 ml (18.2 oz).
  4. Clean the fill plug and apply adhesive GM P/N 12345493 (Canadian P/N 10953488) to the threads.
  5. Install the fill plug (1). Tightening torque Tighten the fill plug to 39 N.m (29 lb ft).
  6. Lower the vehicle.

Scheme 35

Scheme 35: Removal Procedure
Scheme 35: Removal Procedure

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
  2. Drain the transfer case fluid. Refer to «Removal Procedure»(ref-268442-S08297091782007102300000) .
  3. Remove the propeller shaft. Refer to «REMOVAL PROCEDURE»(ref-268433-S18162167032007102300000) .
  4. Remove the right wheel drive shaft. Refer to «REMOVAL PROCEDURE»(ref-268434-S25842646742007102300000) and «REMOVAL PROCEDURE»(ref-268434-S11449327392007102300000) .
  5. Remove both catalytic converters. Refer to «REMOVAL PROCEDURE»(ref-268435-S33781526622007102300000) and «REMOVAL PROCEDURE»(ref-268435-S39884259272007102300000) .
  6. Remove the transfer case mounting bracket bolts (1).
  7. Remove the transfer case mounting bracket (2).
  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 «REMOVAL PROCEDURE»(ref-268420-S35304409352007102300000) and «REMOVAL PROCEDURE»(ref-268420-S32804772792007102300000) .
  13. Remove the bolts (1) securing the transfer case to the transaxle.
  14. Remove the transfer case (2) from the transaxle.

Scheme 38

Scheme 38: Installation Procedure
Scheme 38: Installation Procedure

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40
  1. Install the transfer case (2) from the transaxle.
  2. Install the bolts (1) securing the transfer case to the transaxle. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) . Tightening torque Tighten the bolts to 50 N.m (37 lb ft).
  3. Install the rear transmission mount and bracket. Refer to «INSTALLATION PROCEDURE»(ref-268420-S00498493022007102300000) and «INSTALLATION PROCEDURE»(ref-268420-S09010316002007102300000) .
  4. Remove the jackstand supporting the transaxle.
  5. Install the transfer case heat shield.
  6. Install the transfer case mounting bracket (3).
  7. Install the transfer case mounting bracket bolts (1). Tightening torque Tighten the bolts to 50 N.m (37 lb ft).
  8. Install the transfer case mounting bracket bolt (2). Tightening torque Tighten the bolts to 23 N.m (17 lb ft).
  9. Install the transfer case mounting bracket (2).
  10. Install the transfer case mounting bracket bolts (1). Tightening torque Tighten the bolts to 50 N.m (37 lb ft).
  11. Install both catalytic converters. Refer to «INSTALLATION PROCEDURE»(ref-268435-S37942799152007102300000) and «INSTALLATION PROCEDURE»(ref-268435-S26008271992007102300000) .
  12. Install the right wheel drive shaft. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT (AWD)»(ref-268434-S27983068882007102300000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT (FWD)»(ref-268434-S36590426872007102300000) .
  13. Fill the transfer case with fluid. Refer to «TRANSFER CASE FLUID REPLACEMENT»(ref-268442-S21042108552007102300000) .
  14. Lower the vehicle.

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