How to Replace a Corvette Half-Shaft U-Joint - Page 4

Next, place a new u-joint sans bearing cups in the trunion, install the bearing cups using either the 7/8 socket/mallet combo or the Zip tool, install the snap retainer clips and tap them home as shown in the previous steps.

Joining the trunion with the half-shaft is the next step. Insert the remaining ends of the u-joint (with bearing cups removed) into the half shaft, then place a bearing cup on one end.

Repeat the installation procedures as before to seat the bearing cups using either the Zip tool or the socket/mallet combo again. Then install the snap retainer clips and make sure they are seated properly.

Here's the half-shaft with new u-joints at both ends, ready to go back in the car.

The half-shafts I removed from this car had lock washers on the trunion retaining bolts, which was OK but not correct; they should have had french locks to keep them from coming loose, so a set of french locks was obtained from Zip products and used for the reinstallation. Start by seating the bearing cups in the differential spline, but don't secure them yet, so you can wiggle or move the half shaft as required to install the trunion bolts with french locks, which is the next order of business.

After tightening the trunion bolts, use a screw driver to bend the ears of the french locks down against the heads of the bolts; this will prevent them from working their way loose.

Insert the u-bolt in the spline holes after making sure the bearing cups are seated properly. Use a mallet to tap it home. Install the other u-bolt as well, rotating the tire as required to access to it.

Install the lock washers and nuts on the u-bolts and use a gear wrench to tighten them down. Rotate the tire and re-check tightness of the nuts on both u-bolts, then proceed to install the half-shaft on the opposite side of the car, repeating all of these procedures.

Lower the car and take the Corvette for a test ride. Start out slowly and gradually increase your speed until you reach highway cruising speed. All the while, keep your stereo turned off and listen for any sounds that aren't normal and any vibrations. If everything checks out OK, you've done the job properly and you can relax and enjoy the rest of the ride.