Rear Output Shaft Seal and Bushing Installation

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Rear Output Shaft Bushing, Seals & Special Tools

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) Procedure If the bushing was removed, a new bushing must be installed. Ensure the bushing is installed squarely into the bushing bore. Follow the steps above in the Preliminary Procedures 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 and Super 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