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. 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). Install the NEW bushing on the finger section of the DT-48734 (Heavy Duty) or J 45380 (Light Duty). Install the finger section to the forcing tube assembly of the DT-48734 (Heavy Duty) or J 45380 (Light Duty). Position the bushing and tool to the rear case half. Install the bushing until the tool bottoms on the rear case half. Use the appropriate 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) 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.
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).
Install the NEW bushing on the finger section of the DT-48734 (Heavy Duty) or J 45380 (Light Duty).
Install the finger section to the forcing tube assembly of the DT-48734 (Heavy Duty) or J 45380 (Light Duty).
Position the bushing and tool to the rear case half.
Install the bushing until the tool bottoms on the rear case half.

Use the appropriate 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)
J 45380 Transfer Case Rear Bushing Remover and Installer (Light Duty)