REAR SUSPENSION, DIFFERENTIAL AND HALFSHAFT RESTORATION 1963 TO 1979

REAR SUSPENSION

The rear suspension may be broken down as follows:

1. Differential.

2. Axle 1/2 shafts.

3. Rear torque arm assemblies.

4. Rear brakes.

5. Drive shaft.

6. Misc. parts: drive shaft, rear spring, strut rods, shock mounts, shocks, nuts bolts and mounting hardware.

If the complete rear suspension is to be removed, rebuilt and reinstalled the basic labor and parts cost can be estimated for each of the above units. In most cases the labor to remove and install a Corvette rear suspension will cost about the same with a few exceptions.

For example, if a Corvette is from back east and badly rusted it may require a great deal more in the way of labor and parts to rebuild the rear suspension. A rusted rear suspension can be very time consuming and harder to deal with than one without rust. Where there is heavy rust involved, bolts snap, castings can break and threads must be repaired. All rusted parts must be sand blasted and repainted so as to stop the rust.

The estimates below will be based on the assumption the Corvette we are working on has a clean rust free rear suspension to start with.

Remove and install rear suspension labor $________

Rusted or damaged rear suspension-----add time and materials

DIFFERENTIAL

Once the differential has been removed from the Corvette, it is disassembled and all it’s parts are hot tank cleaned, and all the castings are bead blasted. After cleaning, all the differential parts are inspected for wear.

Again, as with the transmission, we have what I call the hard parts and soft parts.

The soft parts are all the parts included in a rebuild kit. The rebuild kit includes: All the side yoke bearings, inner case bearings, pinion bearings, side yoke seals, pinion seal, pinion nut, positraction, thrust washers, shims, snap rings, cover gasket and gear oil.

The hard parts are all the parts not required for a standard rebuild such as: ring and pinion gear set, inner and outer case, side yokes, spider gears and cross shaft, front yoke and back cover.

As in a transmission rebuild, if everything goes as planned all that is required would be the soft parts kit and labor. If the differential is found to be in very poor condition the labor to rebuild it will stay the same, however, the cost will depend on it’s condition.

For example, if the ring and pinion gear set is worn out, or the side yokes are not usable, or the inner case is cracked (a fairly common problem), the parts cost may increase by several hundred dollars. In most cases, if the Corvette has been treated well and this is its first differential rebuild, the hard parts are usually reusable.

I have seen other cases, especially in the older Corvettes, where everything but the outer case and back cover must be replaced. The only option here, assuming numbers match isn’t a consideration, is to find a good used replacement differential or install all new parts in the original case.

Standard rebuild labor $________

Parts rebuild kit $________

Additional parts as required

AXLE HALF SHAFTS

The universal joints are removed from the axle half shafts, the flanges and axle tubes are cleaned and inspected. Assuming the axle tubes are straight, the u-joint press fit surface is good and the flanges are in good shape, they will be painted and reassembled with high quality u-joints.

PARTS $_________

LABOR $_________

Additional parts as required.