Lock It Up! Install a Mini-Spool in Your Chevy

With the bolt out of the way, the pin can be removed. Stop! If you are doing this job with the housing out of the car like we were with the pinion pointed down, insert a piece of cardboard or sheetmetal under the carrier. It will make your life much easier when the C-clips fall out and don't get trapped in the pinion bearing area. Now push the axles toward the center and remove the C-clips. With these clips gone, pull the axles out several inches. This would be a good time to replace the axle seals.

All four spider gears can now be removed. Note there are spacers behind each one. These spacers must go back in with the new parts.

First, with its spacer, place each splined block in the carrier. At this time, insert the axles. Do this carefully, using one hand to push the axle and the other to hold the splined block in place. Do this on both sides.

With the axles pushed all the way in, the C-clips can be installed. Coat the C-clips with a heavy grease to keep them from falling out during assembly. Once the C-clips are in place, pull outward on the axles to set the clips into their recesses.

Rotate the carrier until the slots in the splined blocks are aligned. The square blocks must now be paired with their cupped spacers. As mentioned earlier, the holes on the curved side of the blocks must be chamfered to match the cupped spacers.

Rotate the carrier so that both blocks with their spacers can be inserted in the slots of the splined blocks. Now rotate all four blocks--not the carrier--until the holes in the square blocks line up with the pin. This may take a few tries, but it is not difficult.

Once the holes in the carrier align with the holes in the square blocks, the pin may be inserted. The end of the pin with the bolt hole must be matched with the hole in the carrier. I can't tell you what to torque it to because of the method it was removed and installed. Get it tight and use a drop of red Loctite(TM) to secure it.