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So I'm suspecting the positraction clutches may be going out. Once the entire differential is out of the car, is it a difficult rebuild process? If I paid someone to rebuild it how much would I expect to pay for the entire job? Does anyone have the procedure written up on-line?
I just had a friend of mine rebuild mine. He has done hundreds of rear ends, but never a C5 rear end. He works for GM and told me that it's good that I got new clutches and springs because the factory clutches suck. The new HD clutches that I bought from RevXtreme have lines cut into them so they can get proper oiling. Also the HD springs are much better. The factory rear ends are notorious for breaking these springs rendering the posi almost useless. He charged me 275.00 including all the new seals and gaskets and whatever else needed to be replaced. 150.00 was his labor and the rest was his cost on the parts. He replaced both shafts with the 4340m (300m) shafts too.
Rev Extreme is close to you, and can handle the rear end rebuild. We are in Jacksonville and can as well.
The biggest problem with rebuilding the C5 rear diff is the special tools that are required, there is only a couple of them but they are rather expensive
I once rebuilt a 4L60e, and I remember getting HD clutches for that from a place in Atlanta called APD.
Do you know if the new c6s have better differentials? The differential always "seemed" to be a weak link for many C5 folks.
What's the deal with the shafts you mention?
Yes. Tracy Lewis at RevXtreme in Bradenton Fl. The C6 Z06 rear end is better, but you'll have to replace the entire cradle to use it and I don't remember what else you'll have to do.
As for the shafts, you will discover their weakness if you're making any significant power, launching hard or wheel hopping. ( Wheel hopping is a big no no. You can break anything doing that.) There is an upgrade that costs 300 bucks for the drivers side which is the weakest and I think it's about 550.00 for the passenger side including the gear required to install it.