For those of you that did this swap what did you do when you bolted on the c6 side covers? My c6 covers had the o-ring on the inside corner of the cover and it fit down into a recess cut in the diff housing. The c5 has a chamfer in the diff housing and an o-ring groove cut into the fitment part of the side cover. I was under the impression that it was a direct bolt on(replacing the covers). I even tried doing a search after to see if I had just missed it. It for the most part bolts right up except I had to drill and tap one new hole on only one of the sides and without the step(it has a chamfer) cut in the c5 diff it wont allow the cover to tighten flat against the diff. I machined an o-ring groove in my c6 covers(was tricky putting it in the lathe with that long arm swinging) and its all good now. Unless I have some sort of Bastar**** parts then this is by no means something you could bolt right together in your garage. The scary part is that if you didn't know better you could put it together like it was and and the bearing clearance would be way out on the cover that has the outer race in it. Id like to hear from those of you that have done this and see what ways you resolved this. I have went my own direction on constructing the new rear mount that makes it a complete bolt-on part with rubber still utilized. I will take some pics and share after tomorrow most likely.

 

It’s a direct “Bolton” if you use the correct bracket. You can’t expect the diff to just bolt in without using the conversion parts. The C6 diff is bolted to the cradle on the sides. The C5 bolts to the cradle right in the middle. Here is a link that’ll help you understand the conversion a bit more.

http://forums.corvetteforum.com/c6-t...et-update.html

 

I understand the differences in how they mount. My question is what did you do about the o-ring style difference between the two covers. If you bolt the c6 cover on the c5 diff without making a change you will potentially damage the cover by bending or cracking the tabs on the cover by over tightening because the o-ring cannot compress without a proper step to receive it. Ill attach some pics of the direction I took on the rear conversion mount which I made as direct bolt on with no welding or drilling. The lower triangle shaped piece fits in the cradle pocket and fits up against the ledge .......
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[IMG] Uploaded with ImageShack.us[/IMG]
[IMG] Uploaded with ImageShack.us[/IMG]

 

Another way to skin this cat! Always appreciate you guys with the tools and ingenuity to tackle these yourself.

They used the stock c5 side covers in my conversion. So far so good, it's got 145 runs on it and 18,500 miles on it to date.

 

Great info on C6 A4 / C5 Diff swap! Thanks!

 

perfect this is exactly what i been looking for for my 05

 

Norm did a great job on that machine work