Q: What steps should be taken to clean and inspect the differential case components and associated parts for damage and wear on Chevrolet Corvette?
A: Clean the differential case components in solvent and examine for cracks, damage, unusual wear, clustered bolt holes in case, scored or gouged carrier side bearing mounting flanges, unusual wear or scoring of clutch pack. Wash with solvent the gears and shafts and examine the gears for chips and cracks, discoloration due to heat, excessive wear or scoring of the side gear pin bores, unusual or excessive wear or grooves on the side gear pin, side gear washers all damaged by wear/scoring unusual and wear or grooves on the output gear splines, damage to the ring gear threaded bolt holes and wear or damage to the ring gear vehicle speed sensor reluctor ring lobes. Check the shafts for abnormal wear out, grooved, worn, or scratched splines, as well as damaged C-clip grooves. Clean the discs and plates with solvent and check them for any abnormal wear: wear, scoring or groove on separator plate friction surfaces, uneven wear or worn friction material on friction plates, bent or warped plates or discs, worn, scored or collapsed bellville washer. Examine the bearing rollers and cups for pitting, scoring, grooves, excessive wear and other damage and look out for heat discoloration which varies from a faint yellow to a dark blue - the latter suggests possible overload or insufficient lubrication; bearings or cups with heat discolorations must be replaced. Also, look for bent or broken bearing cages, looking to the left side cover output shaft bushing for worn or absent needle bearings.