TRANNY AND TORQUE ARM
MOUNT INSTALLATION
The trick is to get the car off the ground with 4
jack stands, one on the frame at each corner. For the tranny
mount, remove the mount nut, put a bottle jack under the
tranny, and lift slightly. Remove the 4 crossmember bolts
and the 2 mounting bolts. Put on the new mount (1 plate, 1
mount, 2 bolts) and bolt up the crossmember. Lower the
tranny and screw the new bolt into the mount to tighten.
The torque arm mount is more involved, but straight
forward. You need to have the suspension at full travel
since the two rear bolts holding the torque arm to the
differential are very long and need to come out the top.
Remove those 2 bolts and slide the torque arm out of bushing
and out of way. Then go to work on the front bracket. Remove
the entire bracket from the car (2 bolts with nuts, 1 nut,
and 1 bolt). Then you need to grind/drill out 4 rivets.
Using a grinder makes it fairly easy although time consuming
(about 20-30 minutes). Then lube the new bushing, slide it
into bracket, put bracket back on and tighten all the bolts
except the one that tightens the 2-piece bracket together.
This makes it a little easier to put the torque arm back in.
Slide the torque arm into the bushing. Get the rear of the
arm aligned and drop the two rear bolts back thru it. Then
tighten the front bracket bolt and tighten the rear bolts.
Finally, lower the car.
REAR DIFFERENTIAL
FLUID CHANGING
First, you'll need the following:
- 2 quarts of rear differential fluid (i.e. Mobil-1
75W-90, synthetic)
- 1 bottle (4 oz.) of GM Limited Slip Additive
(available at any GM dealer)
- 1 rear differential gasket (also from any GM dealer or
auto parts store)
- 1 tube of Permatex or Locktite NON-HARDENING
adhesive/sealer
- 1 ratchet with 1/2" socket and open-end wrench of
the same size
- Sharp razor blades (preferably with a handle/holder)
- Large oil pan to catch the old fluid
The Old Fluid:
Wear old clothes as the old differential fluid stinks and
the smell will never totally come out of your clothes. Back
the car onto car ramps or jack it up under the rear
differential and put jack stands on each side of the axle
and lower the jack to rest the car (axle) on the jack stands
(you could leave the jack under there, but it will only get
in the way).
Place the oil pan under the differential housing (you may
want to prop it up up on a box to get it as close as
possible to prevent splashing). Remove all the differential
bolts with the ratchet (the very bottom bolt will require
the open-end wrench as the sway bar is in the way), but do
not remove the very top bolt. Just loosen it. This will hold
up the rear cover preventing it from splashing down into the
pan w/ the fluid. Also note that the bolts at 10 and 2
o'clock are longer than the rest of the bolts to accommodate
the brake line brackets. These bolts must go back into the
same holes they came out of.
The seal on the cover should be tight enough that the
cover won't break free after removing the bolts. So gently
pry on the bottom of the cover with a screwdriver to loose
it up (if necessary). Even though you left the top bolt
slightly in to hold up the diff cover, pry slowly until the
fluid starts to trickle down since pulling the cover open
will cause a splash down of fluid and you won't smell pretty
after that.
Once most of the fluid has drained, remove the top bolt
and the cover and wipe out the inside of the cover with some
rags. Try to especially get the metal shavings off the
magnet inside. Scrape off all of the old gasket with a razor
blade to ensure the new gasket will make a proper seal. Also
check the edge of the differential housing under the car to
scrape any old gasket off of there as well.
At this point, it's suggestible to lower the car off the
jacks/ramps since the housing is at an angle and lowering it
allows any additional fluid to drain. It also makes the
housing level so when you put in the new fluid, you don't
over/underfill it. Using a rag, wipe out any fluid sitting
in the bottom of the housing.
The New Fluid:
Apply the non-hardening sealer/adhesive around the entire
edge of the cover and firmly attach the new gasket (no
sealer is needed on the housing side). Put the cover back
onto the housing and tighten all of the bolts. Keep
tightening all of the bolts around the differential in a
circular pattern to ensure all are equally tight (30 N-m or
22 lb-ft if using a torque wrench).
On the right side of the housing (passenger side), there
is a square-inset/ plug which the ratchet (without a socket)
will fit perfectly into. This is the filler hole. Remove it
with the ratchet and squeeze the bottle of GM Limited Slip
Additive in first. Put in the new fluid (about 1.5 quarts)
and keep filling until the fluid starts to come out of the
filler hole down the side of the housing. Then it's full.
You might want to pour the fluid through a small piece of
rubber tube since the filler hole is on the side of the
housing and at a weird angle to pour. Finally, replace and
tighten the filler cap (35 N-m or 26 lb-ft).
REAR GEAR SWAP WITH
AUTOMATIC TRANNY
While the following doesn't detail exact instruction
for swapping rear gears on your own, it will describe the
process and what's needed in order to do the swap on a 4th
generation car with an automatic transmission where the
speedometer has to be adjusted for the change.
If your car came from the factory with the standard Good
Year 235/R55/16 Eagle GAs tires (which are non Z-rated),
then it most likely has a computer controlled speed limiter
that cuts off the fuel pump at about 108 MPH. Getting rid of
the speed limiter is going to be part of the desired effect.
If, on the other hand, your came from the factory with
Z-rated Good Year 245/ZR50/16 Eagle GSCs or RSAs, then you
shouldn't have a speed limiter. Only wind resistance
prevents your cars going over 160 MPH.
There are advantages and disadvantages to swapping gears.
The assumption here is that you are swapping to a shorter
gear (numerically higher - i.e. from 2.73 to 3.23 gears).
The only real disadvantage of swapping is going to be gas
mileage. If you don't want to experience a significant
change, especially highway gas mileage, forget about a gear
swap. Also, a slight loss in theoretical top-speed will
result depending on how short of a gear you use. The main
advantage is better acceleration. The lower ratio will get
the tires turning much faster.
As for the ratio, you have a number of choices. The 4th
gens have a GM 10 bolt 7 5/8 inch rear end. This is a
different rear end than goes into the Corvette and other GM
vehicles. Therefore, the 3.08 rear axle ratio will not fit.
Unless you change to an entirely different rear axle,
housing and all, your ratio choices are limited to 3.23,
3.42, 3.73, or 4.10. However, 4.10 gears with an automatic
are a bad choice as the engine will just rev too high at
highway speeds.
Your rear axle has a ring and pinion, and it has a
positraction (Auburn limited slip differential) carrier.
There is also something called an ABS reluctor gear. If you
go to a gear shop, and they install U.S. Strange or Richmond
gears, the positraction carrier doesn't have to be replaced.
While opinions differ on this, it's recommended that you
stick with factory GM gears. They are reliable and quiet.
However, if you have currently have 2.73s and plan on going
to GM gears of 3.23 or shorter, you're going to have to
replace your stock 2 series carrier with a 3 series carrier.
Additionally, there is an ABS sensor located on the top
of the axle housing and an ABS reluctor gear that is
attached to the carrier. The ABS sensor reads the reluctor
gear as it turns around inside the axle. On a car with a 2
series carrier (stock 2.73), this gear is only about 1/4
inch wide. If you change to a 3 series carrier, you need a
new reluctor gear which is 1/2 inch wide. If you use the old
reluctor gear, your ABS INOP warning light will come on
because the ABS sensor cannot read the reluctor. It's well
worth the $18 cost for the new reluctor gear.
Have the work done by reputable gear shop that knows what
they are doing. Forget the dealer unless they promise you,
in writing, an iron clad price with a warranty prior to
beginning the work. A new Auburn 3.xx limited slip posi is
going to cost about $300-$350. The entire job is going to
cost you about $950 including installation, new factory GM
gears, and a new carrier. About $150 of that cost is for
labor. It is a 2-3 hour job. There is also a 200 mile break
in period required for the new gears.
After the swap, you need to reprogram your on-board
computer (ECM) adjusted so the speedometer and odometer get
recalibrated to the new gears. This is entirely a computer
controlled issue. Assuming you have an automatic 4L60E
(electronic) transmission, the ECM thinks that the car has
the old gears. The Power Programmer from Hypertech
(901-382-8888), will reprogram the ECM to properly adjust
the speedometer and odometer, in addition to removing the
speed limiter. The programmer also adjusts the wide open
throttle shift points. However, one thing that it doesn't do
is alter your part throttle shift points. For this, you need
to send your computer to Hypertech (or one of many other ECM
companies) so they can reprogram all the part throttle shift
points to match your new gears. Because after a gear swap,
your part throttle shifts will be out of synch. Since
shorter gears rev higher, the stock ECM will still be
shifting at its preset points. So the engine may hit 3000 or
4000 RPM before shifting (whereas before it should shift at
2000 RPM under partial throttle). You may be tolerable of
this, but the ideal thing to do is have the part throttle
shifts reprogrammed.
CYBERDYNE BOX
INSTALLATION
Cyberdyne sells a box which can recalibrate your
speedometer. You can get one from JEGS, Summit, or a local
speed shops for around $65, There are 5 wires coming out of
the box: red (to ign switched +12v source), black (ground),
white (incoming speedo signal), blue (outgoing corrected
speedo signal), and blue/black striped (don't know - leave
it unconnected).
The black wire can be tapped off a shifter cable mounting
bolt, and red wire can be tapped off a radio circuit line
behind the reciever. For a hot lead, you should probably run
one from the fuse box. The grommet for the the shifter cable
should be deteriorated enough to poke two wires through to
meet up with the speed sender. At the very back of the
tranny tailshaft (on the driver side) is the sender with two
wires: one yellow (the signal) and one purple (ground). Cut
the yellow wire, solder the connections and cover them
extensively with electrical tape.
Go for a test drive (with the box dangling) before
permanently attaching it. The cyberdyne box has two small
adjusters, one coarse and one fine. You'll probably have to
mess around with the adjusters (especially the coarse one)
to get a reasonable reading. The cyberdyne box nestles
nicely between the wiring harness bundle and the brake
interlock cable and shouldn't need to be fastened down.
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