Ok, now with much greater understanding on rear end setups I have run into another snag. I guess the Torsen rear has just perfect c-clip retainers that fit the end of the axles into them. Well I R2 my axles as they had wear and potentially caused my noise. However the new axles do not have the same tips they are slightly larger on the tip and it looks like the axles I pulled out have the tips machined to fit.... Any Ideas besides taking them down to a machine shop?
The good news is as I was setting up the carrier I noticed that I needed another shim as they where not so hard to put in and this slop could be the culprit for the noise around right had turns as the shim I added was on the right side, this would allow the ring to move farther from the pinion on right hand turns. God I hope that was the noise....

Here is the retainer.

Here is the old axle measurements


Then the New axle measurements

 

Ok so I got the new axles machined to fit and they seem to fit very well. I got the rear end all put back together and the noise when turning right is gone!!! Only thing is there is a new noise, I first noticed it as I pulled the car out of the garage, it was a loud chirping sound. it doesn't do it every rotation and it does it in a straight line even without throttle. At first I thought it was the brakes. But it doesn't go away with application of the brakes. I did not drive it far and pulled it back into the garage. Could this be the axle bearings I just installed? I pulled the wheels off and there is a very minute bit of end play with the axles. should I be able to move the axle at all up and down? Im gunna head to the store to get some new seals so I can pull the bearings to check them, and I will measure the end play as well.

*UPDATE* I took off the brakes and the sound went away for the short drive, I then put them back on for the sound to have gone... and like .5 mile into the test drive it came back... it wasn't a consistent noise. Its sounds like the wear plates on the brakes but the brakes are still good. I think I will do a good go through with the rear brakes and see if I cannot quiet them up.

 

I too get a consistent chirp from the right rear brake on my camaro. I have just been too cheap too fix it. BTW it is normal to have endplay on the axle shaft.

 

A couple things I've noticed when working on these 10 bolts - I've seen wear in the pockets where the c-clips fit in to the carrier because the c-clips have a sharp side and a rounded side and if that sharp side was assembled facing the pocket, either that is rubbing when you make a turn or the c-clip is rubbing on the other side of the axle groove, something is going to grind a little bit. After time, that can contribute to excess axle end play. And if the calipers are locked up or can't move in and out a little bit on their pins, then the brakes will also have a problem from the axle moving in and out.

 

thanks for the heads up with the c-clip installing smoothe side facing in. I noticed a little wear on the c-clips but not really any on the carrier. I think when I was driving in my lugs I may have bent the caliper a little(enuff to make contact with normal end play)
I did notice this slight wear on both calipers(as sugested proof of c-clip wear) The thing that kills me is the brakes did not make this noise with the old axles at all.(and I know its the brakes hitting because there is now evidence of them rubbing. They didn't even touch that area before as it was covered in rust in the spot that is now rubbing.
Im going to pull it apart again this weekend and check more indepth to see if I cannot find a simple solution.

 

Not sure this is the solution as it sounds like an intermittent problem but GM makes a .024 shim (p/n 26034667) which goes in between the axle tube and the caliper axle plate to allow for additional outboard adjustment of the caliper mount. The LT1 spec from inboard side of the caliper plate to outside of axle flange is 2.70 to 2.74.

 

I fixed the issue. It was the caliper hitting I guess the axles aren't so direct fit as advertised on summits site. Anyway a couple washers and the calipers now fit perfect no noise!!!!!!!!!!!!!!!!!!!!! WOOOOOOOOOOOOOOH!!!!!!
I didn't want to cut any materiel away from the caliper and I didn't think a thin washer would cause any problems with the brake spacing. The threads have plenty inside as this was only .005 difference. Both sides seem perfect... Thanks for every ones help. This site is a must for the DIY guy!