Transfer Case Rear Extension Bushing Replacement

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Fig 1: Transfer Case Rear Extension Bushing

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
CAUTION: Refer to Transfer Case Seal Removal Caution . Preliminary Procedures: Remove the transfer case rear output shaft seal. Refer to Rear Output Shaft Seal Replacement .
1	Transfer Case Rear Output Shaft Bushing Procedure Install the finger section of the DT-48734 (Heavy Duty) or J 45380 (Light Duty) in front of the bushing. See Special Tools . Install the forcing tube assembly into the finger section. Ensure the forcing screw is backed out. Using a wrench on the forcing screw, remove the bushing. Remove the old bushing from the DT-48734 (Heavy Duty) or J 45380 (Light Duty). See Special Tools . Install the NEW bushing on the finger section of the DT-48734 (Heavy Duty) or J 45380 (Light Duty). See Special Tools . Install the finger section to the forcing tube assembly of the DT-48734 (Heavy Duty) or J 45380 (Light Duty). See Special Tools . Position the bushing and tool to the rear case half. Install the bushing until the tool bottoms on the rear case half. Tip: Use the appropiate bushing tool depending on application. Only remove the bushing if faulty. If the bushing was removed, a new bushing must be installed. Ensure the bushing is installed squarely into the bushing bore. Special Tools DT-48734 Transfer Case Rear Bushing Remover and Installer (Heavy Duty). See Special Tools . J 45380 Transfer Case Rear Bushing Remover and Installer (Light Duty)

Callout

Component Name

CAUTION: Refer to Transfer Case Seal Removal Caution .

Preliminary Procedures: Remove the transfer case rear output shaft seal. Refer to Rear Output Shaft Seal Replacement .

Transfer Case Rear Output Shaft Bushing

Procedure

Install the finger section of the DT-48734 (Heavy Duty) or J 45380 (Light Duty) in front of the bushing. See Special Tools .
Install the forcing tube assembly into the finger section. Ensure the forcing screw is backed out.
Using a wrench on the forcing screw, remove the bushing.
Remove the old bushing from the DT-48734 (Heavy Duty) or J 45380 (Light Duty). See Special Tools .
Install the NEW bushing on the finger section of the DT-48734 (Heavy Duty) or J 45380 (Light Duty). See Special Tools .
Install the finger section to the forcing tube assembly of the DT-48734 (Heavy Duty) or J 45380 (Light Duty). See Special Tools .
Position the bushing and tool to the rear case half.
Install the bushing until the tool bottoms on the rear case half.

Tip:

Use the appropiate bushing tool depending on application.
Only remove the bushing if faulty.
If the bushing was removed, a new bushing must be installed.
Ensure the bushing is installed squarely into the bushing bore.

Special Tools

DT-48734 Transfer Case Rear Bushing Remover and Installer (Heavy Duty). See Special Tools .
J 45380 Transfer Case Rear Bushing Remover and Installer (Light Duty)