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Before I start this I should point out that I am in fact not a Transmission specialist. I am a general tech who just happens to dabble in everything and try new things. That being said, if any actual Transmission Techs out there want to chime in with pointers, correct me, add stuff, whatever...please do so. I'm not a genius and i'm also writing this up months after i actually did it, so i may have missed something or typed it wrong. I'm not going to cry if you criticize me, I care more that the correct info is out there for the people who need it. The following how-to is a step by step process of how to change out your transmission Output Shaft. This is actually part of a massive retrofit I'm doing over HERE to swap AWD into my RWD SSS. In case you didn't know, the only major difference between an AWD and RWD transmission in your SSS is the output shaft. The RWD has a longer Output Shaft because it has a tail housing going directly to the driveshaft. The AWD has a short "stub" shaft that goes into the NV-149 Transfer Case adapter, then T-case, which connects to the driveshaft. Anyone who has tried to put high HP into their truck knows that these transmissions are actually utter crap and can't handle power. Quick bit of history. The silverado used to use the 4L60E, but due to increases in power, especially with the SS version, they revised it into the 4L65E. A few revised parts here and there, and boom a transmission that can still barely handle the power being put into it. Most everyone has had their transmission go out or had a friend's who's did. 70,000 miles here...intake, exhaust, daily driver. Don't get discouraged though, a good reputable builder can build you a 4L65E that can last. Anyway back on point, one of the many weak parts in this transmission is the AWD output shaft. So the long RWD shaft while put under stress actually flexes a bit to help alleviate said stress. The shorter AWD shaft though does not, so when said stress is exerted, say hundreds of pounds of torque suddenly applied, the shaft will just straight break. Luckily you can find shot-peened, cryo-treeted, electrical induction treated, billet, etc shafts all over the internet. Now if you decided to tackle an output shaft replacement/swap you'll find that the ouput shaft is actually close to the back of the transmission and 3/4 of the guts have to be removed to get to it. A real pain, but not all that hard. Much easier than a full transmission rebuild. If you have a manual and patience this can be done in a few hours. For my purposes though i have to replace the RWD long shaft with the short AWD shaft for my build.
Well, I am in the process of preparing to take out my transfer case and split it open to replace my rear output shaft bearing. I have looked everywhere for a video or good pics of what it takes to do. I am pretty mechanically inclined and think I can do this job. I just do not like any suprises that will stop my progress. I looked at various types of Chevy transfer case disassembly videos on youtube but can not find the NP149 disassembly at all. I knoe about the snap ring that holds on the rear half of the case and the snap ring in front of the output shaft bearing. What Iwould like to know is does the output shaft bearing have to be pressed on or off and if so what else is involved with removing the shaft from the case. If anyone has experience with this please let me know. Thanks for the help.