Standard Assembly

Fig. 1 Exploded view of rear axle assembly. Except Corvette:

1. If side carrier bearings are to be replaced, remove bearings using a bearing puller.
2. Remove differential pinion shaft lock bolt and the pinion shaft, Fig. 1.
3. Remove differential pinions and thrust washers, side gears and side gear thrust washers, noting installation position for assembly. Keep thrust washers with respective gears.
4. 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.
5. Inspect components as outlined in CLEANING & INSPECTION and replace as needed.
6. Install thrust washers on side gears and mount side gears in case. Lubricate all components with specified gear lubricant prior to assembly.
7. Position one differential pinion (less thrust washer) between side gears and rotate gears until pinion is directly opposite case loading opening.
8. Install other pinion with pinion shaft holes aligned, then rotate side gears and ensure pinions align with shaft openings in case.
9. When pinions are properly aligned, rotate pinions toward loading opening just enough to allow thrust washer installation and install washers.
10. 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.
11. 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.
12. 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.
13. Alternately torque ring gear bolts to 89 ft. lbs.
14. Press side bearings onto case. If old bearings are reused, ensure bearings are installed in their original position.