I put the rear end back together on Saturday. I went over to GTR Friday night to use their bearing removal tool and press but the tool they had was rounded on one side and it didn't work. So Saturday morning I took my grinder and cut the old bearings off. I cut them down so there was just a thin bit a metal left and then tapped them with a hammer which cracked them thin metal. Then I just slid them off by hand. Before I installed the new bearings I clearanced the teeth on the ring gear so I could install the pin. Here's how it turned out.
Then on Sunday I put the transfer case back together, which was a pain to do without a good pair of snap ring pliers. I had to remove a snap ring on the main shaft so I could remove it from the rear portion of the case to reassemble it but my cheap pliers would just bend. The only tool I had that I could spread it far enough with was a pair of small needle nose pliers. So I had Amy use a flat head screw driver to push it while I used the needle nose pliers. Once I got the case back together I installed it back in the truck along with the front and rear driveshafts, the exhaust and the fuel tank.
Everything is now working again. Well except that the amp went out so it doesn't have a radio but that's just how it goes. The truck has been sitting for a couple weeks and I forgot that the amp quit working. It's a 5 channel Sony and is about 11 years old. I'll have to wait for my income tax return before I can replace it with another 5 channel amp though.
