Differential Assembly: Adjustments

1. Ensure differential case flange is free of nicks and burrs, then install ring gear on case using new bolts. Torque attaching bolts to 80 ft. lbs. Tighten bolts evenly so that ring gear will be properly seated on case.
2. Install master differential bearings J-34170 on 7.874 inch axles or J-35505 on 8.5 inch axles.
3. Assemble case assembly into carrier and install bearing caps with retaining bolts finger tight, then mount dial indicator to supporting fixture.
4. Force differential case away from pinion gear until completely seated against carrier cross bore face. With force still applied to case, place dial indicator plunger on a flat machined surface of differential case, if available, or on the head of a ring gear screw. Zero dial indicator.
5. Force ring gear to mesh with drive pinion. Rock gear slightly to ensure gear teeth are meshed and note dial indicator reading. Repeat procedure several times to ensure the reading is accurate. Ensure dial indicator reads zero each time the case is seated against cross bore face. The reading, .006 inch for preload and backlash adjustment will be the size of the shim pack between differential case and differential bearing on ring gear side.
6. Remove dial indicator, differential case and master bearings.
7. Assemble shim pack as determined in step 5 to ring gear side hub, then install bearing cone.
8. Take measurement obtained during differential side bearing preload adjustment and subtract shim pack dimension determined in step 5. The resulting dimension should be .015-.020 inch on models with 7.874 inch axle or .008-.012 inch on models with 8.5 inch rear axle.
9. Assemble shim pack as determined in step 8 to hub opposite ring gear, then install bearing cone.

Fig. 2 Spreader tool installation. Corvette:

10. Install spreader tool, J-24385-01, adapter, J-24385 and dial indicator set, Fig. 2. Zero indicator and ensure indicator stylus contacts one side of housing opening.
11. While observing micrometer, spread housing with tool. Do not spread housing more than 0.010 inch or distortion could result.
12. Assemble differential bearing cups on case, then install case in rear housing. If necessary, use a soft faced hammer to seat case in carrier cross bore.
13. Install bearing caps and bolts. Ensure letters stamped on caps correspond in position and direction with letters stamped in carrier. Torque bolts to 45 ft. lbs. on models with 7.874 inch rear axle or 63 ft. lbs. on models with 8.5 inch rear axle.
14. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is .006-.009. Backlash cannot vary between points checked more than .001-.0015.
15. If backlash is excessive, move shims from side opposite ring gear to ring gear side, but do not change the combined total thickness of both shim packs.
16. If backlash is too small, move shims from ring gear side to side opposite ring gear, but do not change the combined total thickness of both shim packs.
17. Install inner yoke shafts into carrier, then the shaft snap rings. Check axle shaft endplay. If endplay is not within .0005-.0085 inch, install thicker or narrower axle shaft snap ring as necessary.
18. Install axle housing cover with RTV or gasket to rear housing and install bolts.
19. Install rear axle assembly. Refer to AXLES, DRIVESHAFT/COMPONENT R&R/PROPELLER SHAFT.
20. Add four ounces of limited slip additive No. 1052358 or equivalent to rear axle, then top off with rear axle lubricant No. 1052271 or equivalent.