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Jontis -- Gary walked me through a rebuild and with his help, it wasn't too bad. You might want to get his paper and see the list of tools you will need and make sure you have access to them.
I've read Gary's papers and posts on rebuilds and found them excellent. They also convinced me that now is not the time to learn to rebuild the differential if it can be avoided. The diff is not the only project I have this winter I was in the process of overhauling the complete front and rear suspension and steering with bushings, derusting, painting and alignments when I noticed that the diff was on it's last breath.
I read hot rods article on beefing up the corvette rear end for heavy duty, mentioning also Tom's work and saying that carbon clutches doesn't hold up.
However, this article was targeting the drag vette niche with +1200 hp applications. My baby will only put out those numbers in my dreams as the previous owner was kind enough to put in the cheapest available goodwrench engine
The carbon fiber clutches are a disaster. As Gary noticed they literally fall apart. They also require the 400# preload springs just to make them work along with having to add .050 shim to take up the slack. The new solid steel clutches are great. They don't wear or break.
Mike
If you are near Clearwater, FL, I'd recommend Alan's Gearworks. I had them blueprint a new Dana 44 unit I bought for my '80 (service replacement unit from eBay) and they even added 3.54 Spicer gears... This unit has performed flawlessly... $450 for the rebuild/blueprint/gears... I carried it into the shop so no shipping charges in my cost. They are well-known in the Tampa Bay area as a quality shop.
With the weight and freight costs (europe), a rebuild of my own pumpkin didn't feel like a good choice. I ended up getting a unit rebuilt by Van Steel that they found local. I have been most impressed by the help and service I have received from Dan Dorsett and Van Steel and would recommend them. On recommendations from Mike, Gary and the forum, I ditched the idea of carbon clutches and went from a 3.08 to a 3.36 ratio (350 4 spd manual) and I'm happy with the switch. I do wish for an overdrive on the highway but that will be a later project.
I also want to thank all you on the forum. This winter I have restored the complete front suspension, rear suspension, steering and mid-rear driveline. This '72 vette is my first car and I really didn't know a thing about cars before I got it. None of this would have been possible without your help. Thanks again