CV Axle - Rear

This procedure covers removal and replacement of the rear U-joint driveshaft assembly on a 1966 Corvette with independent rear suspension, as C2 Corvettes use a solid rear axle with U-joint halfshafts rather than CV axles.

Warnings

Tools required

Parts

• Rear axle U-joint halfshaft assembly × 1 — Use OEM specification or Spicer/Dana equivalent
• U-joint bearing caps (if servicing U-joint only) × 1 — Spicer 5-153X or equivalent
• U-joint snap rings × 4 — Internal C-clips for yoke
• Differential side yoke seal × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Chock front wheels securely.
3. Loosen rear wheel lug nuts while vehicle is on the ground.
4. Raise rear of vehicle and support securely on jack stands at frame rails.
5. Remove rear wheel on side being serviced.
6. Place drain pan under differential on side being serviced.

Procedure

1. 1

   Remove brake caliper
   Remove the two brake caliper mounting bolts using a 9/16 inch wrench. Support the caliper with wire or a bungee cord to avoid tension on the brake hose. Do not let the caliper hang by the brake line.
2. 2

   Remove brake rotor
   Remove the rotor retaining clip if present. Slide the brake rotor off the hub. If the rotor is stuck, tap gently with a dead blow hammer around the hat section.
3. 3

   Remove wheel hub and spindle assembly
   Remove the spindle nut cotter pin and discard. Using a 15/16 inch socket, remove the large spindle nut. Pull the hub and spindle assembly straight off the axle shaft splines. The outer wheel bearing will come out with the hub.
4. 4

   Remove trailing arm strut rod bracket bolts
   Locate the strut rod bracket bolted to the rear of the trailing arm near the axle shaft U-joint. Remove the two bracket bolts using a 1/2 inch socket. This provides clearance to pivot the axle shaft for removal.
5. 5

   Disconnect axle shaft from differential side yoke
   Locate the U-joint connecting the axle shaft to the differential side yoke. Remove the four U-bolt nuts or U-joint strap bolts (depending on configuration) securing the U-joint bearing caps to the differential yoke using a 1/2 inch socket. Note the orientation of the U-joint and yoke for reassembly.
6. 6

   Remove axle shaft assembly
   Carefully pull the axle shaft outboard while tilting the inner end downward to clear the differential yoke. Differential fluid will drain from the axle tube opening. Allow fluid to drain completely into the drain pan. Remove the axle shaft assembly from the vehicle.
7. 7

   Inspect and service U-joints
   Inspect both U-joints on the axle shaft for wear, binding, or play. If replacing U-joints, use a U-joint press or C-clamp with sockets to press out the old bearing caps. Remove the internal snap rings first. Install new U-joint bearing caps, ensuring snap rings seat fully in their grooves. U-joints should rotate smoothly without binding or excessive play.
8. 8

   Inspect differential side yoke seal
   Inspect the differential side yoke seal at the axle tube opening for leaks or damage. If the seal is leaking or damaged, carefully pry it out and press in a new seal flush with the axle tube face using a seal driver or appropriate socket.
9. 9

   Install axle shaft assembly
   Clean the axle shaft splines and differential yoke with a wire brush. Apply a light coat of gear oil to the splines. Insert the axle shaft into the axle tube, tilting the inner end down to align the U-joint with the differential side yoke. Align the U-joint bearing caps with the yoke bores.
10. 10

    Connect axle shaft to differential yoke
    Install the U-joint bearing caps into the differential yoke bores. Install the U-bolt saddles or bearing cap straps and thread the nuts or bolts finger-tight. Ensure the bearing caps are fully seated in the yoke. Torque the U-bolt nuts or strap bolts to 15-18 ft-lbs in a crisscross pattern.
11. 11

    Reinstall strut rod bracket
    Position the strut rod bracket back onto the trailing arm. Install the two bracket bolts and torque to 30-35 ft-lbs using a torque wrench and 1/2 inch socket.
12. 12

    Reinstall wheel hub and spindle assembly
    Pack the outer wheel bearing with fresh wheel bearing grease if removed. Slide the hub and spindle assembly onto the axle shaft splines, seating it fully. Install the spindle washer and spindle nut. Torque the spindle nut to 50 ft-lbs while rotating the hub to seat the bearings, then back off the nut and retorque to 12 ft-lbs. Install a new cotter pin.
13. 13

    Reinstall brake rotor and caliper
    Slide the brake rotor onto the hub and install the retaining clip if equipped. Position the brake caliper over the rotor and install the two caliper mounting bolts. Torque the caliper bolts to 70-75 ft-lbs using a 9/16 inch wrench or socket.
14. 14

    Refill differential fluid
    Locate the differential fill plug on the rear cover or housing. Remove the fill plug using a 3/4 inch socket. Add 75W-90 GL-5 gear oil through the fill hole until fluid reaches the bottom of the fill hole threads (approximately 2 quarts total capacity). Reinstall the fill plug and torque to 25-30 ft-lbs.
15. 15

    Reinstall wheel and lower vehicle
    Install the rear wheel and thread the lug nuts by hand. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to 70-80 ft-lbs in a star pattern. Lower the vehicle completely and remove jack stands.

Reassembly

1. Ensure all fasteners are torqued to specification.
2. Verify differential fluid level is correct at the bottom of the fill plug threads.
3. Check for any fluid leaks around the axle tube seal after test drive.
4. Verify brake caliper is properly secured and brake pedal is firm before driving.

Verification

• Test drive vehicle at low speed and verify no abnormal noises from the rear axle.
• Check for vibration or binding during acceleration and deceleration.
• Verify smooth operation through turns in both directions.
• Recheck differential fluid level after test drive and top off if necessary.
• Inspect for any fluid leaks at the axle tube seal and differential cover.

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