Rear Cover Assembly: Disassembly

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, 2003 Chevrolet Cab & Chassis Silverado, and 2002 GMC Sierra. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Although there are 4 types of rear cover assemblies, procedures given are the same for all types, unless specified. See Fig 1.

Position rear cover on workbench so rear of cover is facing downward. Remove internal retaining ring from inside housing. See Fig 2, Fig 3, Fig 4 or Fig 5 .
On all except 1000 series 4WD, if rear cover needle bearing assembly requires replacement, position rear cover on press, with rear end upward. Press tone wheel and needle bearing assembly from rear cover.
On 1000 series 4WD, if rear cover needle bearing assembly requires replacement, position rear cover on workbench, with rear end upward. Use a suitable drift and tap needle bearing assembly from rear cover.
On all series, position rear cover on workbench with rear end facing downward. Gently pry C5 clutch piston from rear cover. Remove seal rings from C5 clutch piston. See Fig 2, Fig 3, Fig 4 or Fig 5 .
If equipped with a tachograph plug, position rear cover on workbench with rear end upward. Remove tachograph plug and washer.

Fig 1: Identifying Different Rear Cover Assembly Configurations