How to Service and Repair Differential Bearings for the Z06 on Chevrolet Corvette?

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Start by unscrewing and removing the j 42168-9 (2) and corresponding thumbscrew from the j 42168-1 (1) rod of the Differential side bearing, then remove the actual bearing (J 42168-1 (1)) from the housing with precision. Set the dt-48009-2 on a vice, align the bearing cup (2) to it and insert the Differential case (1) into the bearing cup (2). After this, rotate the Differential in both directions to evenly fit the bearing into its groove. Insert the dt-48009-3 (2) into the hole of dt-48009-1 (1) and run the eccentric to lay against the bottom of the bearing race bore. Place the dt-48009-3 (2) under the ring gear of the Differential (1), holding it in place with a ring gear bolt and turn the Differential until the dt-48009-3 shaft (2) is above the dt-48009-2 gage block (3). Use a feeler gage to measure the distance between the dt-48009-3 (2) rod and the dt-48009-2 (3) gage block. Write down the value as dimension c1 and then subtract it from 3 mm (0.118 in) to obtain c2. Measure the distance from the ring gear side to the a2 point and record it as c3. Next, subtract the nominal value of 65.8 mm for d from the value for c3 to get c2 and then add the two together for the correct shim thickness on the left Differential bearing. Choose shims that are the closest match to your calculated thickness. Unscrew the Differential pinion housing/cage bolts and remove it and the housing from the Differential. Gently pull out the j 42168-11 (1), bearings (2 and 5), spacer (4) and dt-48009-1 (6) from the pinion housing/cage (3) with the assistance of the dt-48008. Place a dt-48008 mount, j 42170 pad and use a hydraulic press to mount the Differential shim and bearing race into the Differential housing. Afterward, affix the ring gear to the Differential while appropriately aligning with various bolts and employing a hammer and brass punch as needed. Use a torque wrench set to 195 n.m (144 lb ft) for the first design bolts or 145 n.m (107 lb ft) for the second design bolts to tighten the new ring gear bolts. Place the Differential assembly inside the j 42173, fit the Differential case into the Differential housing by means of the j 42155 and attach the bearing cup and j 42168-15 to the Differential. Take out the right cover oil seal and check that the pinion housing/cage has not yet been installed for the shim assessment. Bolt the right cover (2), the j 42168-16 bolts (1) and spacers (3) using 30 n.m (22 lb ft) of torque. Check the play between the bearings using a feeler gage inserted into the j 42168-15 part and loosen the bolts and cover to determine the appropriate shim for the right side bearing setup. Next, insert the right side bearing shim (2) and the bearing cup (1) into the right cover using the j 42170 tool and a hydraulic press.

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