How to Remove C6 rear differential - 2005 Chevrolet Corvette

remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Remove the brake caliper. Refer to Rear Brake Caliper Replacement.

Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement.

Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.0/8.6 Inch Axle) ' Rear Axle Housing Cover and Gasket Replacement (9.5 Inch Axle).

Remove the pinion shaft locking bolt
On axles without a locking differential, remove the pinion shaft.
(learn what locker means and does) or read the RPO list on car.
On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.

1. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the C-lock?(1) until the C-lock aligns with the thrust block?(2).
2. Push the flange of the axle shaft?(1) toward the differential.

remove the C-lock from the button end of the axle shaft.
read the manual first.
if he bearing is seized up and they can swell up and be tight
the slide hammer is the only cure here. and is always best to use.
(after all pre steps on 3 different axle types) not told by you.

1 get the RPO first from GM
2; then read the manual.
3: then act.

easy as 1,2,3 ,not guessing and doing damage.

Special Tools

• Slide Hammer
• Axle Remover

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the brake caliper. Refer to Rear Brake Caliper Replacement.
4. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement.
5. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
6. Remove the pinion shaft locking bolt.


7. On axles without a locking differential, remove the pinion shaft.


8. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.


9. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the C-lock?(1) until the C-lock aligns with the thrust block?(2).
10. Push the flange of the axle shaft?(1) toward the differential.


11. Remove the C-lock from the button end of the axle shaft.

Note: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the installing of the axle shaft difficult.
12. Remove the axle shaft from the housing.
13. Hope this helps?

The stall in a converter is when the internal parts of the converter lock and has the same rpm,s as the engine. Transferred to the transmission input shaft. Factory is 1000 to 1500 rpm stall. Put another way. You have a 1500 stall converter, when you floor the gas pedal and the rpm,s go to 1500 real fast, the rear tires will spin faster than the vehicle is going. Don't put a larger stall in a vehicle that isn't built to take the torque. Ie.. Upgraded engine, transmission and rear differential. Some thing will break.

Hi, welcome to FixYa.com my name is Shawn and I will be answering your question.

Remove the differential rear cover.
Remove the rear calipers and rotors.
Remove the 8mm bolt that holds the pin in and remove the differential pin.
Remove the ABS sensors push the axle in towards the center of the rear end.
Remove the c clip washers. You can now pull the axle out.

I hope my assistance helped you and resolved your concern, if you need further assistance please ask.

what about it?

conventional axle or limited slip? Get axle code off door sticker.

SECTION 205-02: Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear 1998 Explorer/Mountaineer Workshop Manual
IN-VEHICLE REPAIR Rear Wheel Bearing and Axle Shaft Oil Seal -4.0L SOHC and 4.0L EI, Conventional
Special Tool(s) Axle Seal Replacer
T83T-1175-A Axle Wheel Bearing Puller
T83T-1225-A Axle Wheel Bearing Replacer
T83T-1225-B Driver Handle
T80T-4000-W Impact Slide Hammer
T50T-100-A
Removal

1. Remove the axle shaft; refer to Axle Shaft in this section.

Axle Shaft Removal

1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel (1007) and the rear wheel bearings (1225).
   Loosen the lug nuts (1012).
   1. Remove the center cap.
   1. With the weight of the vehicle on the wheels, loosen the lug nuts.

1. Raise and support the vehicle.

1. Remove the wheel and tire assembly.
   1. Remove the lug nuts.
   1. Remove the wheel and tire assembly.

1. Remove the axle housing cover (4033).
   1. Loosen the axle housing cover bolts (4346) and drain the rear axle (4001).
   1. Remove the axle housing cover bolts.
   1. Remove the axle housing cover.

1. Remove the rear disc brake rotors (2C026); refer to Section 206-04 .

1. CAUTION: Once the differential pinion shaft (4211) has been removed, turning the differential case (4204) or an axle shaft (4234) will cause the differential pinion gears (4215) to fall out of the assembly. This could result in chipped or damaged components.
   Remove the differential pinion shaft.
   1. Remove the differential pinion shaft lock bolt.
   1. Remove the differential pinion shaft.

1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves.
   Remove the U-washers (4N237).
   1. Push the axle shafts inboard.
   1. Remove the U-washers.

1. Reinstall the differential pinion shaft.
   1. Install the differential pinion shaft.
   1. Install the differential pinion shaft lock bolt finger-tight.

1. CAUTION: Do not damage the inner wheel bearing oil seal (1177).
   Remove the two axle shafts.

Installation

1. Lubricate the lip of the inner wheel bearing oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components.
   Remove the differential pinion shaft.
   1. Remove the differential pinion shaft lock bolt.
   1. Remove the differential pinion shaft.

1. CAUTION: Do not damage the inner wheel bearing oil seal.
   Install the two axle shafts.

1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves.
   Install the U-washers.
   1. Position the two U-washers on the button end of the axle shafts.
   1. Pull the axle shafts outward.

1. Install the differential pinion shaft.
   1. Align the hole in the differential pinion shaft with the differential pinion shaft lock bolt hole.
   1. Install the differential pinion shaft lock bolt.

1. Install the rear disc brake rotors; refer to Section 206-04 .

1. Install the axle housing cover and fill the rear axle housing (4010) with 2.4 liters (5.5 pints) of specified lubricant; refer to Axle Housing Cover in this section.

1. WARNING: Always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheel or the surface of the wheel hub or rear disc brake rotor that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
   Clean the wheel hub and mounting surfaces.

1. Install the tire and wheel assembly.
   1. Position the tire and wheel assembly.
   1. Install the lug nuts and lower the vehicle.
   1. Tighten the lug nuts.
   1. Install the center cap.

1. CAUTION: Never remove the axle shaft oil seal by itself. Always remove the rear wheel bearing and the axle shaft oil seal at the same time.
   NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with debris.
   Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and the axle shaft oil seal.

Installation

1. Lubricate the new rear wheel bearing.
   1. Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

1. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing.

1. Lubricate the lip of the new axle shaft oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. Use Axle Seal Replacer with Driver Handle to install the axle shaft oil seal.

1. Install the axle shaft; refer to Axle Shaft in this section.

to remove the rear axle you will need to put the rear of the jimmy on jack stands off the ground and remove the wheels

then remove the rear drums or if you have disc brakes the caliper and rotor

next you will need to remove the rear differential cover

once you have removed the rear differential cover you will need to rotate the differential by just turning the rear axle to gain access to the lockbolt

using an 8 mm socket you should be able to fairly easily remove the lock bolt

once you have removed the lock bolt you will need to push the axle in from the side that the wheel gets mouted to and then in the rear differential remove the locking 'c' clip

once the locking 'c' clip is removed you should be able to pull the axle right out

installation is the reverse of the removal

keep in mind that after romoving the lock bolt you must make sure not to rotat the axle if you do you will mess up the allignment with the differential and axle and you will spend loads of time trying to re-allign it again

hope this helps

Removal

1. Raise vehicle and place jackstands under rear frame crossmember. Lower the hoist so that rear axle housing is at suitable working height.
   

1. Remove axle housing cover from rear axle housing and drain lubricant.
   

1. Perform the inspection before disassembly.
   

1. Remove rear wheels, rear disc brake calipers and rear disc brake rotors.
   
2. Working through cover opening, remove differential pinion shaft lock pin and remove differential pinion shaft and differential pinion gears (4215).

NOTE: THIS IS FREE INFORMATION!!!!

1. Remove rear brake anti-lock sensor . Push axle shaft inward until u-washers at button end of the axle shaft are clear of side gear recess.
   

1. CAUTION: Do not damage inner wheel bearing oil seals when removing axle shafts from rear axle housing. In addition, axle shafts should be completely removed from rear axle housing.
   Remove u-washers and pull axle shafts out of the rear axle housing.

Axle Vent
NOTE: If the vent cannot be cleared, it must be installed new.
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanics wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done. The vent is located on the drivers side top of axle housing.
If you plan on doing most repairs yourself I would suggest buying a Haynes or Chilton manual for your particular vehicle. Or there are some data disks on e.bay($12-$15) For a cost of under $25, you can almost do any repair yourself with these manuals.Also there are online manuals like the site called ALLDATA where guides can be viewed for a fee. All these solutions will save you time and money, and give peace of mind over correct repairs. I can post you some procedures here also.

1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel (1007) and the rear wheel bearings (1225).
2. Loosen the lug nuts (1012).
3. Remove the center cap.
4. With the weight of the vehicle on the wheels, loosen the lug nuts Raise and support the vehicle. .Remove the wheel and tire assembly.
   
5. Remove the lug nuts.
   
6. Remove the wheel and tire assembly. Remove the axle housing cover (4033).
   
   1. Loosen the axle housing cover bolts (4346) and drain the rear axle (4001).
   1. Remove the axle housing cover bolts.
   1. Remove the axle housing cover.
   

7.Remove the rear disc brake rotors You will have to remove the brake caliper to get rotor off.
8. CAUTION: Once the differential pinion shaft (4211) has been removed, turning the differential case (4204) or an axle shaft (4234) will cause the differential pinion gears (4215) to fall out of the assembly. This could result in chipped or damaged components.
9.
1.Remove the differential pinion shaft lock bolt. 2.Remove the differential pinion shaft. 10.CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Remove the U-washers (4N237).

1. Push the axle shafts inboard.
2. Remove the U-washers.

11.Reinstall the differential pinion shaft.
1. Install the differential pinion shaft.
1. Install the differential pinion shaft lock bolt finger-tight.

12.CAUTION: Do not damage the inner wheel bearing oil seal (1177). Remove the two axle shafts.

CAUTION: Never remove the axle shaft oil seal by itself. Always remove the rear wheel bearing and the axle shaft oil seal at the same time. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with debris. Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and the axle shaft oil seal.

Axle bearing puller end..
Installation
Lubricate the lip of the inner wheel bearing oil seal.
Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components.
2. Remove the differential pinion shaft.
3. Remove the differential pinion shaft lock bolt.
4. Remove the differential pinion shaft.

CAUTION: Do not damage the inner wheel bearing oil seal. Install the two axle shafts. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers.
1. Position the two U-washers on the button end of the axle shafts.
1. Pull the axle shafts outward.

Install the differential pinion shaft.
1. Align the hole in the differential pinion shaft with the differential pinion shaft lock bolt hole.
1. Install the differential pinion shaft lock bolt.

Install the rear disc brake rotors; Install the axle housing cover and fill the rear axle housing (4010) with 2.4 liters (5.5 pints) of specified lubricant
WARNING: Always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheel or the surface of the wheel hub or rear disc brake rotor that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub and mounting surfaces. Install the tire and wheel assembly.
Position the tire and wheel assembly. Install the lug nuts and lower the vehicle. Tighten the lug nuts. Install the center cap. WHEW Hope this can help you

SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Axle Shaft Removal

1. Raise and support the vehicle. For additional information, refer to Section 100-02 .

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .

1. Remove the differential housing cover (4033) and drain the lubricant. For additional information, refer to Differential Housing Cover in this section.

1. Remove the differential pinion shaft (4211).
   1. Remove the differential pinion shaft lock bolt (4241).
   1. Remove the differential pinion shaft.

1. CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
   Remove the U-washer (4N237).
   1. Push the axle shafts (4234) inboard.
   1. Remove the U-washer.

1. CAUTION: Damage to the rear brake anti-lock sensor (2C190) may occur if it is not removed before the axle shaft.
   Carefully remove the rear brake anti-lock sensor. For additional information, refer to Section 206-09A .

1. CAUTION: Do not damage the wheel bearing oil seal.
   Remove the axle shaft.

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Rear Wheel Bearing and Axle Shaft Oil Seal Removal

1. Remove the axle shaft (4234). For additional information, refer to Axle Shaft in this section.

1. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged.
   Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.

Installation

1. Lubricate the new rear wheel bearing with the specified lubricant.

1. Using the special tools, install the new rear wheel bearing.

1. Lubricate the lip of the new wheel bearing oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. Using the special tools, install the new wheel bearing oil seal.

1. Install the axle shaft. For additional information, refer to Axle Shaft in this section.

-------------------------------------------------------------------
Installation

1. Lubricate the lip of the wheel bearing oil seal
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. CAUTION: Do not damage the wheel bearing oil seal.
   Install the two axle shafts.

1. CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
   Install the U-washer.
   1. Position the two U-washers on the button end of the axle shaft.
   1. Pull the axle shaft outward.

1. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.
   Install the differential pinion shaft.
   1. Align the hole in the differential pinion shaft with the case lock bolt hole.
   1. Install a new differential pinion shaft lock bolt.

1. Install the differential housing cover and fill the rear axle with the specified lubrication. For additional information, refer to Differential Housing Cover in this section.

1. Install the rear brake anti-lock sensor. For additional information, refer to Section 206-09A .

1. Install the rear brakes. For additional information, refer to Section 206-04 .

1. Install the tire and wheel assembly. For additional information, refer to Section 204-04 .

1. Lower the vehicle.

Axle Shaft Removal

1. Raise and support the vehicle. For additional information, refer to Section 100-02 .

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Remove the differential housing cover (4033).
   1. Loosen the bolts and drain the lubricant from the rear axle housing (4010).
   1. Remove the bolts.
   1. Remove the differential housing cover.

Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .

1. CAUTION: Turning the differential case (4204) or an axle shaft (4234) with the differential pinion shaft (4211) removed will cause the differential pinion gears (4215) to fall out of the assembly and damage the components.
   Remove the differential pinion shaft.
   1. Remove the differential pinion shaft lock bolt.
   1. Remove the differential pinion shaft.
2. CAUTION: Do not damage the rubber O-ring in the U-washer groove.
3. Remove the U-washer (4N237).
4. Push the axle shaft inboard.
5. Remove the U-washer.

Reinstall the differential pinion shaft.

1. Install the differential pinion shaft.
2. Install the differential pinion shaft lock bolt finger-tight.
3. CAUTION: Do not damage the wheel bearing oil seal (1177).
   Remove the axle shaft.

-----------------------------------------------------------------------------------------------------------------
Seal Removal

1. Remove the axle shaft (4334). For additional information, refer to Axle Shaft in this section.

1. CAUTION: Never remove the wheel bearing oil seal (1177) by itself. Always remove the rear wheel bearing (1225) and the inner wheel bearing oil seal at the same time.
   NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material.
   Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.

Installation

1. Lubricate the new rear wheel bearing.
   • For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
   • For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

1. Using the special tools, install the rear wheel bearing.

1. Lubricate the lip of the new wheel bearing oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. Using the special tools, install the wheel bearing oil seal.

1. Install the axle shaft. For additional information, refer to Axle Shaft in this section.