1. Preparation and Safety:
* Safety First: Disconnect the battery negative terminal. Use jack stands securely under the frame, never rely solely on a jack. Wear safety glasses and gloves.
* Gather Tools: You'll need a comprehensive set of tools including various sockets, wrenches (metric), a torque wrench, jack stands, a floor jack, a transmission jack (highly recommended), possibly a pickle fork or similar tool for separating ball joints, and a drain pan for fluids.
* Consult the Service Manual: Obtain a factory service manual for your 1995 Chevy Z71. This is crucial for precise torque specifications and detailed procedures.
* Fluid Drainage: Drain the differential fluid completely.
2. Disconnecting Components:
* Wheels and Brakes: Remove the wheels and brake calipers. You may need to use a C-clamp to compress the caliper piston to allow you to remove the rotor. Support the caliper carefully to prevent damage to the brake lines.
* Drive Shaft(s): Disconnect the drive shafts at the differential. This usually involves removing bolts and possibly a retaining clip.
* Brake Lines: Carefully disconnect the brake lines from the axle housing. Be prepared to plug the lines to prevent fluid loss.
* Shocks/Struts: Disconnect the shocks or struts from the axle.
* Control Arms and Suspension Links: Disconnect any control arms, suspension links, or other components connected to the axle housing. This might involve removing bolts and bushings.
3. Axle Removal:
* Unbolt the Axle Housings: The axle housing is bolted to the truck's frame. Locate and carefully remove these bolts. This will likely require substantial leverage and possibly a breaker bar.
* Lowering the Axle: With everything disconnected, carefully lower the axle using a transmission jack. The axle is heavy, so be extremely cautious. Guide it out carefully.
4. Limited-Slip Differential Considerations:
* Carrier Bearing: The limited-slip differential may have a carrier bearing that needs to be addressed. This will likely require a special tool.
* Pinion Nut: Removing the pinion nut requires special tools and procedures to avoid damage to the pinion bearings. It's highly recommended to have a shop press available for this.
5. Reassembly:
Reassembly is the reverse of removal, paying close attention to torque specifications. Use new seals and gaskets where necessary. Properly refill the differential with the correct type and amount of fluid.
Important Disclaimer: This is a simplified overview. The process can vary depending on your specific truck's configuration. Attempting this without experience and the proper tools can lead to damage to your vehicle or personal injury. It's strongly recommended to seek professional help from a qualified mechanic, especially given the limited-slip differential's complexities. Incorrectly reinstalling the pinion nut, for example, can lead to catastrophic failure of the rear end.
