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I’m replacing some seals and installing a new clutch. I separated the differential from the transmission and discovered this damage inside the differential. Has anyone seen this on their differential? This may be reason I have a small leak here. Not sure what, if anything, I should do here.
Strange but ok. I was hoping I could have told the wife I needed to replace the diff with 4.10s but I guess I’ll stick with what I have.
I like your thinking!! Honestly, it looks like a cast in "window", like a spot to maybe see the pattern on the gear teeth more clearly. I've never had the cover off, so I don't know what its for, but judging by the gently radiused "lip" you see on each side leading to the area you're referring to, it looks like it was cast in, and is probably on every C5 diff....
Its very normal and NOTHING to be concerned over..
On another note, While you have the DIFF OUT, it would be an excellent time to disassemble it and check for broken limited slip differential clutch Belleview springs. More C5 differentials have broken springs that non broken springs. I have an 02 ZO6 and mine were broken/cracked at 40K miles. I replaced the springs with the better C6 ZO6 springs and also installed new limited slip clutches as mine were worn because of the bad Belleview springs.
I also installed C6 ZO6 output shafts which are much stronger and better design that the Whimpey C5 shafts.
NOTE.. Make sure that you replace the large O ring that seals the differential to the transmission. Otherwise you will have an differential lube leak.
Ya know, As mechanical as I am, I had the same fears. It really isnt that difficult or complicated. There are ZERO alignments that need to be done to reassemble it. The ONLY part that slows people down is using a press to compress the one clutch pack so you can slide in the spider gear cross shaft. I made a little tool out of a piece of heavy wall pipe and it went very easy. Trust me,, If I can do it, you can.
I second Bill's statement. Every new project seems daunting but this one isn't all that bad. Just take your time and let us know when any questions pop up. I replaced my springs years ago, I can almost guarantee yours will be broken too, you did the hard part of taking the diff out already.
Agreed, broken springs and heavily worn clutch packs means no force to remove cross shaft. But getting it back in with new clutch packs and C6Z springs... it'll take some force.
My obligatory toasted clutch packs and Belleville springs picture:
It is most likely stuck to the magnets in the bottom of the case. If your spider gears are not broken, your very lucky and that part of the broken spring just fell all the way down to the bottom. You have my number and if you need to call me. With broken springs, there qill not be any pressure or force on the clutch packs and that cross shaft will just slip out. When you put the new clutches and springs in, you will have to compress that one clutch pack and spring to get the shaft in.
Differential damage? Anyone see this before?
I like your thinking!! Honestly, it looks like a cast in "window", like a spot to maybe see the pattern on the gear teeth more clearly. I've never had the cover off, so I don't know what its for, but judging by the gently radiused "lip" you see on each side leading to the area you're referring to, it looks like it was cast in, and is probably on every C5 diff....
