Rear Output Shaft Seal and Bushing Installation

WARNING: This page is about a different car, the 2009 GMC Yukon, 2009 Chevrolet Tahoe, 2009 Chevrolet Suburban, and 2009 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Rear Output Shaft Seal and Bushing

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
Preliminary Procedures: The following procedure is for the light duty application, for the heavy duty and super heavy duty applications. Refer to Rear Output Shaft Bushing Replacement .
1	Transfer Case Rear Output Shaft Bushing (Light Duty) Tip: If the bushing was removed, a new bushing must be installed. Ensure the bushing is installed squarely into the bushing bore. Follow the steps below for use of the J 45380: remover/installer. Install the bushing on the finger section of the J 45380: remover/installer. Install the finger section to the main body of the J 45380: remover/installer. Position the bushing and tool to the rear case half. Press the bushing until the tool bottoms on the rear case half. Special Tools: J 45380: Transfer Case Rear Bushing Remover and Installer
2	Transfer Case Rear Output Shaft Seal (Light Duty) Tip: Align the notch on the seal between the rear output bearing retaining ring access holes, this will position the weep hole down. Special Tools DT-48210: Seal Installer J 8092: Driver Handle
3	Transfer Case Rear Output Shaft Seal (Heavy Duty) Tip: Align the notch on the seal between the rear output bearing retaining ring access holes, this will position the weep hole down. Special Tools DT-48021: Seal Installer J 8092: Driver Handle