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Installing & Adjusting Differential Side Bearings

WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the Holding Strap (J 42168-9) and thumbscrew from the Differential Centerline Cylinder (J 42168-1). Remove the J 42168-1 from the left bearing race bore of the differential housing.
  2. Install the Gauge Plate Assembly (J 42168-13) into a vice. Position the bearing race onto the J 42168-13. Use the Differential Holding Fixture (J 42173) in order to position the differential case onto the J 42168-13 and into the bearing race. Rotate the differential, in both directions, in order to seat the bearing to the race.
  3. Install the Depth Gauge (J 42168-7) into the hole in Shim Gauge Assembly (J 42168-2). Loosen the thumbscrew and allow the rod to contact the bottom of the bearing race bore, machined surface. See Fig 1. Tighten the thumbscrew. Remove the J 42168-7 from the J 42168-2.
    Fig 1: Setting Depth Gauge
    G00061888Courtesy of GENERAL MOTORS CORP.
  4. Install the J 42168-7 into one of the two oil passages of the differential. The tapered portion of the tool will wedge and be retained into the differential. Rotate the differential until the rod of J 42168-7 is above the Gauge Plate Assembly (J 42168-13) gauge block. See Fig 2. The J 42168-13 upper gauge block location is used when servicing 2.73 ratio differentials. The lower gauge block location is used when servicing the 3.15 and 3.42 ratio differentials.
    Fig 2: Measuring Side Bearing Shim Clearance
    G00061889Courtesy of GENERAL MOTORS CORP.
  5. Using a feeler gauge, measure the distance between the rod of J 42168-7 and the gauge block of J 42168-13. Record the measurement as dimension "C1". Subtract "C1" value from a "C" nominal value of 0.197 in. (5 mm). Record that calculation as "C2".
    6. NOTE: The "A2" value is a manufacturing variation between the ring gear and pinion. The "A2" value may be higher, lower, or equal to 2.58 in. (65.5 mm), 3.15 and 3.42 ratio differentials, or 2.93 in. (74.5 mm), 2.73 ratio differential, nominal value. When subtracting the "D" nominal value from the "A2" value, the "C3" calculation may compute to a positive, negative, or zero total.
  6. Locate the "A2" value on the side of the ring gear. Subtract the "D" nominal value of either 2.58 in. (65.5 mm) or 2.93 in. (74.5 mm) from the "A2" value. Record the calculation as "C3". Add the "C2" value to the "C3" value for the proper left side differential bearing shim thickness. The "C3" value may be a positive, negative, or zero value.
  7. Select shims equal to the calculated value. It may be necessary to round the shim or shims total to obtain the proper shim sizes. If the shim thickness calculation is past the midpoint value, round the number to the next decimal value. Remove the pinion housing/cage bolts.
  8. Remove the pinion housing/cage from the differential. Remove the Pinion Housing Centering Spacer (J 42168-11), bearings, spacer, and Shim Gauge Assembly (J 42168-2) from the pinion housing/cage. See Figure. Use the Bearing and Race Installer (J 42170) and a hydraulic press in order to install the selected shims and bearing race to the differential housing.
  9. Use the Differential Lifting Tool (J 42155) in order to install the differential case into the differential housing. Install the right side bearing race, and the Side Bearing Shim Selector (J 42168-15) onto the differential. Install the right cover and Spacers (J 42168-16) bolts and spacers to the differential. Position the J 42168-16 bolts and spacers evenly apart. Tighten the bolts to 18 ft. lb. (25 N.m).
  10. Insert a feeler gauge into the J 42168-15 and measure the gap. See Fig 3. The measured dimension is the right side differential bearing shim size.
    Fig 3: Measuring Right Differential Bearing Shim Size
    G00061890Courtesy of GENERAL MOTORS CORP.
  11. Remove the bolts, cover, and tools. Remove the bolts, cover, and tools. Install the shim or shims and bearing race into the right cover using the Bearing and Race Installer (J 42170) and a hydraulic press.
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