Output Yoke/Flange: Service and Repair

Drive Pinion Flange/Yoke and/or Oil Seal Replacement

^ Tools Required
- J 36797 Getrag Axle Output Shaft Seal Installer
- J 44755 Holding Fixture

Removal Procedure





1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Remove the extension housing vent hose (2) and clamp.
3. Remove the propeller shaft.





4. Place a container under the extension housing.
5. Remove the lubricant drain plug (1) and gasket. Allow the oil to drain.





6. Remove the bolts (3), extension, housing assembly (1), and shim (2) from the transfer case. Reference mark the shim for proper reassembly.





Notice: Refer to Fastener Notice in Service Precautions.

7. Install the extension housing assembly (3) to the J 44755 (2) with M8 x 1.25 bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





8. Remove the flange nut (1).
9. Remove the bolts and the extension housing assembly from the J 44 755.





10. Position the extension, housing, assembly into a press.
11. Preps the pinion shaft from the flange.
12. Remove and discard the extension -housing seal.

Installation Procedure





1. Use the J 36797 in order to install a new seal (2) into the extension housing.





2. Position the flange and the extension housing assembly into a press.
3. Lightly lubricate the splines on the yoke.
4. Press the flange (1) onto the driven shaft.





Notice: Refer to Fastener Notice in Service Precautions.

5. Install the extension housing assembly to the J 44755 (2) using M8 x 1.25 bolts (1).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





6. Install the flange nut (1) onto the driven shaft.
^ Tighten the flange nut to 250 Nm (185 ft. lbs.).
7. Remove the extension housing assembly from the J 44755.





8. Measure the rotating torque of the driven shaft in both directions.
^ The driven shaft and bearings should have a rotating torque of 1.5 Nm (13 inch lbs.).





9. Apply sealant GM P/N United States 12346004 GM P/N Canada 10953480, or equivalent to both sides of the shim.
10. Align the reference marks and install the shim (2) to the transfer case.
11. Install the extension housing (1) and bolts (3) to the shim and transfer case.
^ Tighten the extension housing bolts to 28 Nm (21 ft. lbs.).





12. Install the extension housing drain plug (1) and gasket to the extension housing.
^ Tighten the plug to 32 Nm (24 inch lbs.).
13. Remove the extension housing fill plug (2) and gasket.
14. Fill the extension housing with gear oil.
15. Install the extension housing fill plug and gasket.
^ Tighten the plug to 32 Nm (24 inch lbs.).





16. Install the extension housing vent hose (2) and clamp (1).
17. Install the propeller shaft.
18. Lower the vehicle.