1993 #135 in now off the road for the winter. The project list is:
+) F/R wheel bearing/hubs (completed, AC Delco golds used as replacements)
+) Pinion seal replacement
+) Steering column pivot pin replacement
So one project checked off the list and a couple more to go. Before removing the old bearing/hubs I measured deflection at the wheel rim lip. All 4 had noticeable deflections when off the ground and moved by hand. Ranged from 0.025” to 0.040”. One rear came apart when removed from the knuckle. Not sure all 4 are the originals, but now all are fresh.

Brian

 

A few pictures from the pinion seal R&R.

Getting started:

Getting started, viewed form back:

Rear portion of exhaust removed, lots of grease from seepage:

Exhaust removed, driveshaft removed, seal removed (C-beam back in place after seal removal, see below regarding seal issue):

New seal installed and mostly cleaned up:

Pinion flange holder and torque wrench in place ready to tighten pinion nut to spec:


One thing I found out with the 4:10 gears the pinion seal and pinion nut are not the same as with the original gear set. The set up in this car required the Dana 36 pinion seal and pinion nut. I do not know when this gear set was installed, probably 20+ years ago by an owner prior to the person I purchased the car from. But apparently the pinion used has a smaller OD pinion flange and a smaller nut compared to the original gear set. The pinion seal and nut I ordered for a 1993 Dana 44 were not correct, the nut was too larger and the opening in the seal for the pinion flange was too large. The seal I removed and cross referenced the number on it, it turns out to be the seal for the Dana 36.

I torqued the pinion nut per the Dana 44 spec, I wonder if I should torque per the Dana 36 since nut is the smaller size of the 36? Any thoughts on this?

Regards,
Brian

 

So yours is a very early 4.10 that required modifications when installed in the 'vette/viper D44 housing. If you're looking for specs just use any conventional D44 for a GM/FOMOCO D44 rear. How many miles on the car? Do you have any idea when the 4.10 was done? The first give away on the lesser 26 spline D44 is the u-bolt retention at the pinion flange. If you ever required pinion bearings or perhaps a rear rebuild it would be advisable to go to the later correct Super 44 hardware. Is the rear quiet?

The 'vette/viper pinion is actually D60 spec diameter and 29 spline. The setup used for yours has been known to suffer no issues but if you actually plan on 'using' it remember that it's a smaller pinion.

 

I do not know when the gear change was done. It was done by an owner prior to the one I purchased the car from. I shared some photos of the other bolt on mods (headers, exhaust, Z-industry chip, and few others) when I got the car on the ZR-1 Facebook sites and some of the feedback was they looked to be 20+ years ago. Not knowing for sure I suspect the rear gear changes was done at that time as well. There is a noticeable whine from the rear end on coast, it is quite, on load. The car has 46K miles on it. Good info, thanks.
Brian

 

Nice pics! I'm gonna have to replace the pinion seal on my 96. The book says "loosen" the C beam. It appears that you removed the bolts and shoved it over. Did you have to loosen the bolts at the transmission? Any trouble re-aligning everything and getting the C beam buttoned down?

 

I removed the C beam bolts at both ends, transmission and diff. Then moved it aside. I had the transmission supported so it was easy to reinstall the C beam bolts. I think the hardest part is removal and reinstall of the exhaust as those parts are always difficult to separate and the put back together.
Brian

 

Thank you Brian. What did you use to drive the new seal into place?

 

I started it with some gentle taps form a hammer. Then once it was started evenly all the way around, I used my pinion flange holding tool. Placed it over the seal and tapped on that to drive the seal all the way in place.
Brian

 

I see you cut off the stock mufflers and have Borla...rest of the exhaust stock?? How do like the sound, any drone?

 

The exhaust was modded by a previous owner to the one I purchased the car from. So I do not know when exactly the mods were done. The exhaust system is headers, no cats, x-pipe, and the Borla mufflers. The sound is great. It doesn’t drone but it is a little loud, it would get old on a long trip.
Brian

 

Update on steering column pivot pin replacement:
Here is the steering column lowered on to the seat cushion, both side covers removed, my pin puller set up. A thread rod, 8-32, with several washers and a 13mm crows foot line wrench to pull against.

A picture of my pivot pin puller.

After pivot pin removal.

I think the hardest part of this pivot pin replacement is the reinstallation of this dimmer switch slider/actuator and the side cover that goes over it. It takes some fiddling to get it back together. As you fiddle with it all of a sudden it pops back in place correctly. This is the slider that goes in behind the side cover.

New pin reinstalled before side cover is reinstalled.

The hard part done, side cover on. Actuator not seen as it is behind the side cover.

Outer cover reinstalled, column ready to be raised and support bolted back in place.

I purchased my pin from Marc Haibeck and he was helpful with tips for getting the side cover back on. I also found this video on YouTube, link below, that was helpful. It is a pivot pin replacement on a 3rd gen Camaro, and they also show the actuator and side cover details on a column on the bench. Help me get a feel where the parts go because it is not very easy to see with the column dropped down on the seat cushion in a C4 Corvette.
Brian

 

After completion of winter projects I did a quick cold start just to hear the car run. Now I will wait for warmer and dry days to return to western Oregon. Hopefully in a couple of months.

You Tube

Brian