MODULE REBUILD
and into yoke 44. Once all the components are
properly aligned, press shaft 57. Rotate hous-
ing 49 during this procedure to help the shaft
and its related components seat properly.
12. Install output washer 43 and output nut 42.
13. Perform the bearing preload procedure as ex-
plained in Paragraph 5–16p which uses the
rear output housing as an example.
n. Disassembly of the Rear Output Housing
(Foldout 14)
1. Remove retaining ring 64 to remove P4 ring
gear 65.
2. Remove P4 ring gear 65 from rear output hous-
ing 74.
3. Remove output nut 81 and washer 80.
4. Remove rear output shaft 66 by pressing it out
of rear output yoke 79.
5. Remove yoke 79. Check yoke sealing area for
nicks, burrs, or damage.
6. Remove output seal 78 by using tool
J 24171-A. Be careful not to damage the seal
bore areas.
7. Remove output shaft bearing 77 if it is dam-
aged.
8. Inspect bearing cups 76 and 68 for pitting,
scoring, and damage. If the bearing cups need
replacement, remove each bearing cup by us-
ing tool J 3940 or a hammer and a drift.
9. Remove shims 70, 71, or 72, and bearing
spacer 69 from output shaft 66.
10. If bearing 67 on shaft 66 is damaged, replace it.
To remove bearing 67, position the bearing on
the press table and install split bearing puller.
Using a press, press out rear output shaft 66.
o. Assembly of the Rear Output Housing
(Foldout 14)
1. Inspect rear output housing 74 for scoring and
burrs.
2. If removed, install bearing cups 76 and 68 into
rear output housing 74 by using tool J 3940 or
a hammer and a drift.
Copyright © 2005 General Motors Corp.
3. Position bearing 77 into the output housing.
4. Install output seal 78 into the output housing
by using tool J 38547 and J 35921-1.
5. Inspect output yoke 79 seal area for nicks, burrs,
and damage. Measure yoke seal surface; mini-
mum allowable seal journal OD is 76.20 mm
(3.00 inch). If the yoke does not meet the re-
quired specification, replace the yoke.
6. Place output yoke 79 on a press table.
7. Position output housing 74 on the yoke.
8. Inspect rear output shaft 66 for spline damage
and scoring, and if required, replace the rear
output shaft.
9. If removed, install new bearing 67 on output
shaft 66. To install bearing 67, use tool
J 38579-2. Position the bearing and tool
J 38579-2 on the press table, and then carefully
press output shaft 66 into the bearing until it is
fully seated.
10. Install bearing spacer 69, and shims 70, 71, or
72 onto output shaft 66.
11. Press rear output shaft 66 into yoke 79 passing
through bearing 77 and output seal 78, making
sure that the output housing 74 spins freely.
12. Install washer 80 and output shaft nut 81 but
do not tighten.
13. Place P4 ring gear 65 in housing 74.
14. Install retaining ring 64.
15. Follow bearing preload procedure explained in
Paragraph 5–16p.
p. Output Housing Bearing Preload Procedure
(Foldout 14)
1. Install rear output housing 74 on the rear trans-
fer case half 2.
2. Remove output shaft nut 81.
3. Install washer 80 on the output shaft after coat-
ing both sides with sealant.
4. Lube the threads on the output shaft.
5. Install output shaft nut 81 and tighten it to 610–
815 N·m (450–600 lb ft).
5–33