Disassembly

1. Raise and support rear of vehicle, then loosen axle housing cover bolts and allow lubricant to drain into suitable container.
2. Remove axle housing cover, then proceed as follows:
a. Wipe excess lubricant from inside axle housing, then visually inspect parts for wear and/or damage.
b. Rotate gears and check for roughness, indicating damaged bearings or gears.
c. Install dial indicator on axle housing cover flange, then check and record ring gear to drive pinion backlash.
3. Remove rear axles and propeller shaft.
4. If not previously marked, scribe reference marks on differential bearing bearing caps to be used during reassembly, then loosen bearing cap bolts.
5. Using suitable tool, pry differential case, bearing races and shims out of housing until loose in the bearing caps. Remove bearing races, then the differential assembly. Mark side cups and shims for reference during reassembly.
6. If side carrier bearings are to be replaced, remove bearings using a bearing puller.
7. Remove differential pinion shaft lock bolt and the pinion shaft.
8. Remove differential pinions and thrust washers, side gears and side gear thrust washers, noting installation position for assembly. Keep thrust washers with respective gears.
9. Remove ring gear bolts, then the ring gear, driving ring gear from case using drift and hammer. Ring gear bolts have left hand threads. Do not pry between ring gear and case, as mating surfaces will be damaged.
10. Inspect components, refer to INSPECTION and replace as needed.
11. Install thrust washers on side gears and mount side gears in case. Lubricate all components with specified gear lubricant prior to assembly.
12. Position one differential pinion (less thrust washer) between side gears and rotate gears until pinion is directly opposite case loading opening.
13. Install other pinion with pinion shaft holes aligned, then rotate side gears and ensure pinions align with shaft openings in case.
14. When pinions are properly aligned, rotate pinions toward loading opening just enough to allow thrust washer installation and install washers.
15. Align pinions with shaft opening in case, insert pinion shaft through case, install new lock bolt. It is not necessary to torque lock bolt at this time.
16. Ensure ring gear and case mating surfaces are clean and free from burrs, mount gear on case, install 2 new retaining bolts at opposite sides of gear and alternately tighten bolts to draw gear on case.
17. Install remaining ring gear bolts hand tight and ensure gear is squarely seated on case. Always use new bolts of proper type when installing ring gear. Do not reuse old bolts.
18. Alternately torque ring gear bolts to 80-90 ft. lbs.
19. Press side bearings onto case. If old bearings are reused, ensure bearings are installed in original position.

Drive Pinion

1. Scribe reference mark between drive pinion and driveshaft yoke, then hold yoke with suitable tool and remove pinion nut and yoke. If yoke shows wear in the seal-to-flange contacting surface, the yoke should be replaced.
2. Install original pinion nut a few turns on pinion shaft, then using hammer and drift, tap pinion shaft out of pinion housing. Hold gear end of pinion shaft when removing to prevent it from falling from axle housing. On Corvette models, the pinion preload shims may stick to the pinion housing or the rear bearing during removal. These shims must be collected and kept together for use during reassembly.
3. Remove and discard pinion nut and collapsible spacer.
4. If being replaced, remove front and rear bearing races from pinion housing using drift positioned in race slots and hammer.
5. If rear pinion bearing is being replaced, remove using arbor press and adapters. Measure and record thickness of shim which is found under rear bearing.