Suzuki XL7 2007 Service Manual page 1100

3- ii Table of Contents
Transfer Case Control Connector End Views .... 3C–3
Component Location .......................................... 3C–4
Transfer Case Control Component Views.......... 3C–4
Transfer Case Disassembled View .................... 3C–5
Diagnostic Information and Procedures ........... 3C–6
Diagnostic Starting Point - Transfer Case.......... 3C–6
Symptoms - Transfer Case ................................ 3C–6
Noisy in Drive ..................................................... 3C–6
Noisy When Coasting......................................... 3C–7
Intermittent Noise ............................................... 3C–7
Constant Noise................................................... 3C–8
Transfer Case Leak Diagnosis........................... 3C–8
Repair Instructions ............................................. 3C–9
Transfer Case Fluid Replacement ..................... 3C–9
Transfer Case Assembly Replacement.............. 3C–9
Transfer Case Disassemble............................. 3C–11
Transfer Case Cleaning and Inspection........... 3C–17
Rear Output Drive Housing
Cleaning and Inspection................................. 3C–18
Input Shaft Seal Replacement - Right.............. 3C–19
Input Shaft Seal Replacement - Left ................ 3C–20
Front Drive Axle Inner Shaft Seal
Replacement .................................................. 3C–21
Input Shaft and Rear Output Drive Shaft
Cleaning and Inspection................................. 3C–22
Transfer Case Assemble.................................. 3C–23
Specifications.................................................... 3C–30
Fastener Tightening Specifications -
Transfer Case - Getrag 760 ........................... 3C–30
Sealers, Adhesives, and Lubricants................. 3C–30
Approximate Fluid Capacities .......................... 3C–30
Special Tools and Equipment .......................... 3C–30
Special Tools - Transfer Case - Getrag 760 .... 3C–30
Propeller Shafts....................................... 3D–1
General Description ............................................ 3D–1
Propeller Shaft Description and Operation......... 3D–1
Diagnostic Information and Procedures ........... 3D–2
Component Rotational Speed Calculation ......... 3D–2
Diagnostic Starting Point - Propeller Shaft ......... 3D–5
Symptoms - Propeller Shaft ............................... 3D–5
Roughness or Vibration...................................... 3D–5
Ping, Snap, or Click Noise ................................. 3D–6
Knock or Clunk Noise......................................... 3D–6
Scraping Noise ................................................... 3D–6
Squeak Noise ..................................................... 3D–6
Shudder on Acceleration at Low Speed ............. 3D–6
Vibration Analysis - Driveline ............................. 3D–6
Transfer Case Output Flange Runout
Measurement ................................................. 3D–10
Propeller Shaft Runout Measurement .............. 3D–10
Torque Tube Input Flange Runout
Measurement ................................................. 3D–13
Pinion Flange Runout Measurement................ 3D–13
Differential Pinion Input Shaft Runout
Measurement ................................................. 3D–15
Driveline Working Angles Measurement .......... 3D–16
Repair Instructions............................................ 3D–19
Driveline System Balance Adjustment
(Using EVA) ................................................... 3D–19
Driveline System Balance Adjustment
(Without EVA) ................................................ 3D–22
Driveline Working Angles Adjustment .............. 3D–24
Propeller Shaft Phasing Inspection .................. 3D–25
Propeller Shaft Phasing Correction .................. 3D–25
Propeller Shaft Replacement ........................... 3D–26
Specifications .................................................... 3D–28
Fastener Tightening Specifications -
Propeller Shaft ............................................... 3D–28
Sealers, Adhesives, and Lubricants ................. 3D–28
Propeller Shaft Runout Specifications.............. 3D–28
Driveline Runout Specifications ....................... 3D–28