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Differential Right Cover Damage

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Old Sep 23, 2019 | 02:56 AM
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Default Differential Right Cover Damage

Hi guys!
I got a salvaged 2009 Z06 from my buddy (hit a divider). As i was inspecting the damage which included radiator, fan, lower and upper radiator support, rear right wheel, upper control arm and shock along with other minor things.

All that can be replaced but I noticed the right Differential Cover was cracked. The actual cover is not damaged but the webbing where it connects to a mount is cracked.

Doesn't seem like a tough cover to get off. Would I be able to get this welded without any issues in the future?

Or should I get a new cover? Which would require shimming.



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Old Sep 23, 2019 | 08:39 AM
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By the time you fix that car you could go buy one in good shape.
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Old Sep 23, 2019 | 10:23 AM
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Car is tuned with cam, heads were done a few months ago (polish, new valves, guides etc) along with other things. And if i were to buy everything new, I would be in it 18-19k for a ls7 Z06. I think that's a good price for it.
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Old Sep 23, 2019 | 10:38 AM
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The cover can be welded, but it's gonna take a fair amount of filler, and might not be as strong when it's done. Might also distort some, so that needs watched.

FYI, when I had mine apart this spring, I had to replace several of the side cover bolts because when torquing back to 18ft lb or whatever it was, several stretched and broke. They're garbage, and probably TTY bolts for all I know.
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Old Sep 23, 2019 | 11:34 AM
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It will be removed, ill have my friend check it out and see if a bead is possible. If i do end up needing a new cover, what is the proper procedure for tolerance/preload. According to AllData, its just measuring the depth from the old one and new one, and just compensating the difference with shims.

Good idea on the bolts. Ill get those as well!
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Old Sep 23, 2019 | 01:52 PM
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Originally Posted by carney714
It will be removed, ill have my friend check it out and see if a bead is possible. If i do end up needing a new cover, what is the proper procedure for tolerance/preload. According to AllData, its just measuring the depth from the old one and new one, and just compensating the difference with shims.

Good idea on the bolts. Ill get those as well!
Don't quote me on this but I want to say the tolerance on that depth is only around .003. So, not a whole lot. I'd measure very carefully. If the cracks could cause a bad measurement, I'd probably opt to getting a used rear for it and call it a day. I was looking at my pics and I don't really have any good ones to remind me what mine looked like. Where yours is cracked I want to think ins't a critical area. TIG weld that thing and see how it holds up. Gonna have to cut pretty deep to get a good bead down in there. Would prefer someone with experience in welding those, not for the weld, but for the understanding of what else might go wrong after it's heated. Hopefully there's no effect on the rear end.
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Old Sep 23, 2019 | 02:01 PM
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Since its not on the actual cover, and off to the side, reason why im thinking it'll be okay to weld. My buddy is a welder as profession. Worse case scenario is replacing cover and figure out how to find preload vs finding a new differential.
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Old Sep 23, 2019 | 06:23 PM
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I welded one for my customer who spun into the wall @ Fontana speedway at a buck fidy, We didn't pull the diff, just dropped the cradle. Would have been much easier with the diff out & on the bench, that being said he's still racing it to this day wit 0 problems.

WELD IT!
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Old Sep 23, 2019 | 06:28 PM
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I welded one broken just like that, car spun @ a buck fiddy into the wall at Fontana speedway, we just dropped the cradle to get at it! Would have been a lot easier taken out & done on the bench though :-) That being said he's still racing it this way.


WELD IT!
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Old Sep 23, 2019 | 06:34 PM
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Originally Posted by grpweld
I welded one broken just like that, car spun @ a buck fiddy into the wall at Fontana speedway, we just dropped the cradle to get at it! Would have been a lot easier taken out & done on the bench though :-) That being said he's still racing it this way.


WELD IT!
Im going to drop the cradle this weekend and inspect it! With a impact that was able to crack the mount, do you think there is any internal problems? Im guessing those differentials are strong as hell!
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Old Sep 23, 2019 | 07:03 PM
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Im going to drop the cradle this weekend and inspect it!

Good idea!


With a impact that was able to crack the mount, do you think there is any internal problems?

Doubt it, the mounts are a definite week area.
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Old Sep 23, 2019 | 07:16 PM
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Thanks for the reinsurance! ill post a picture when its done!
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