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Reassembling Ring Gear and Differential Housing

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. Install the right clutch pack to the right case. Install the separator plates. Install the friction discs. Install the friction disc (thick). Install the bellville washer. See Figure.
  2. Install the right output shaft and gear, side gears, and washers to the differential right case. See Figure.
  3. Using the Side Gear Compressor (J 42162) and a hydraulic press, compress the bellville washer and clutch pack in order to install the cross pin to the differential right case.
  4. Using an M8 bolt for alignment, properly position the cross pin into the differential right case. The hole in the pin must align with the hole in the case. During final assembly of the case halves, the pin retaining bolt must be able to pass through the hole in the cross pin. With the pin and case aligned, release the pressure from the press and remove the J 42162 and bolt. See Fig 1.
    Fig 1: Installing Cross Pin
    G00061886Courtesy of GENERAL MOTORS CORP.
  5. Install the gear to the left output shaft. Install the "C" clip to the left output shaft. Install the left side bearing to the differential using Bearing and Race Installer (J 42170) and a hydraulic press.
  6. Install the left clutch pack to the left case. Install the separator plates. Install the friction discs. Install the friction disc (thick). Install the bellville washer. See Figure.
  7. Install the left output shaft and gear to the left case. Assemble the case halves. Install the case bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  8. Install the right side bearing to the differential using the J 42170 and a hydraulic press. Install the ring gear to the differential. Use several bolts to properly align the ring gear to the case. A hammer and brass punch may be used to aid in seating the ring gear onto the differential case. Install the NEW ring gear bolts. Position the differential assembly onto the Differential Holding Fixture (J 42173). Tighten the ring gear bolts to specification. See TORQUE SPECIFICATIONS .
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