How to piece together a ZL1 differential swap - lessons learned from the battle

[dentnshell]

The clips worked great!
PN 24205103
I am sure the generic from Doorman would be great (and quicker to get)

[dentnshell]

Originally Posted by hammdo

Here is the tool. I just upgraded my SS diff to an Eaton



http://www.camaro5.com/forums/showpo...&postcount=933

-Don

Interested in renting that tool out??? I have a slight leak on one side... I did not use a driver... Probably should have just kept the seals that were in the diff since I didn't have an install tool.

You can bet I will when it is time to replace it.

[dentnshell]

Originally Posted by hammdo

Here is the tool. I just upgraded my SS diff to an Eaton



http://www.camaro5.com/forums/showpo...&postcount=933

-Don

Don what are the specs on the tool? diameter of inner lip and outer lip. ZL1 vs SS I would assume the seals are a different size.

I see they can be had for under $25... kick myself for not having one. Being unprepared does not pay!

[Roger Stattel]

I am currently going through the swap, spent all night under it and realized it's not a straight swap. Has anyone done a manual ss to an auto zl1 diff, I got the drive shaft to line up with the diff but it's really tight, too tight I'm my opinion. My buddy recommends that I cut it an inch based off of our measurements. Any feedback from someone who has done it. And no u can't use the front of one to the back of the other like some forums say. Splines don't match.
Thanks guys!

[cc-rider]

Originally Posted by Roger Stattel

I am currently going through the swap, spent all night under it and realized it's not a straight swap. Has anyone done a manual ss to an auto zl1 diff, I got the drive shaft to line up with the diff but it's really tight, too tight I'm my opinion. My buddy recommends that I cut it an inch based off of our measurements. Any feedback from someone who has done it. And no u can't use the front of one to the back of the other like some forums say. Splines don't match.
Thanks guys!

The DS length has nothing to do with the zl1 diff you choose (Auto 3.23 vs manual 3.73). The diff is dimensionally exact for both of these diffs. It's the tranny end where the dimensions change. So you can take a manual trans and add either the 3.23 or 3.73 ZL1 diff and you still use the driveshaft made for the manual. If you have a auto trans, you need a zl1 auto driveshaft.

And as you said....and I'll put this in capital letters to emphasize the point and put it to bed once and for all...YOU CANNOT USE THE FRONT HALF OF A SS DRIVESHAFT WITH THE REAR HALF OF THE ZL1. THEY ARE DIFFERENT SIZES AND THE SPLINES DONT FIT. There is a lot of bad info out on the Internet on this, including here on this forum. The sad part is that it's people like the Driveshaftshop saying this. They should know better.

[dentnshell]

Take a look at the instructions... I have not done the manual swap, but would be really confident in the instructions and the parts needed. The strength of the propshaft and bolt sizes are a big reason you would want to swap. Use the part numbers listed and compare them to part numbers of your parts and parts off of the donor car.
The kit calls for a new:
Propshaft -20931145
and
Transmission Flange - 22960154

Don't forget all of the supporting bolts.

[cc-rider]

Originally Posted by dentnshell

The clips worked great!
PN 24205103
I am sure the generic from Doorman would be great (and quicker to get)

Do you just have the little rubber plugs that go in there like I do?

[dentnshell]

The plugs that were identified with the instructions came as aluminum bullets. The inside of that fitting has a small o-ring.

[Roger Stattel]

Originally Posted by cc-rider

The DS length has nothing to do with the zl1 diff you choose (Auto 3.23 vs manual 3.73). The diff is dimensionally exact for both of these diffs. It's the tranny end where the dimensions change. So you can take a manual trans and add either the 3.23 or 3.73 ZL1 diff and you still use the driveshaft made for the manual. If you have a auto trans, you need a zl1 auto driveshaft.

And as you said....and I'll put this in capital letters to emphasize the point and put it to bed once and for all...YOU CANNOT USE THE FRONT HALF OF A SS DRIVESHAFT WITH THE REAR HALF OF THE ZL1. THEY ARE DIFFERENT SIZES AND THE SPLINES DONT FIT. There is a lot of bad info out on the Internet on this, including here on this forum. The sad part is that it's people like the Driveshaftshop saying this. They should know better.

Well I agree with what your saying, but there's 2 factors that are also in play, first I would like to use the zl1 shaft cause It is beefier, also the input shaft on the diff is an inch longer(extend an inch further forward) vs the SS diff, which throws things off a bit.

[cc-rider]

Originally Posted by Roger Stattel

Well I agree with what your saying, but there's 2 factors that are also in play, first I would like to use the zl1 shaft cause It is beefier, also the input shaft on the diff is an inch longer(extend an inch further forward) vs the SS diff, which throws things off a bit.

Yes. But the ZL1 driveshaft takes this into account. I just put the ZL1 shaft on my swap. Fit perfect.

[Roger Stattel]

Were you a manual ss to a zl1 diff? I used both pieces of the zl1 shaft and it fits, it's just really tight in there and the ss shaft coming out was a bit looser.

[Driveshaftshop]

Originally Posted by cc-rider

The DS length has nothing to do with the zl1 diff you choose (Auto 3.23 vs manual 3.73). The diff is dimensionally exact for both of these diffs. It's the tranny end where the dimensions change. So you can take a manual trans and add either the 3.23 or 3.73 ZL1 diff and you still use the driveshaft made for the manual. If you have a auto trans, you need a zl1 auto driveshaft.

And as you said....and I'll put this in capital letters to emphasize the point and put it to bed once and for all...YOU CANNOT USE THE FRONT HALF OF A SS DRIVESHAFT WITH THE REAR HALF OF THE ZL1. THEY ARE DIFFERENT SIZES AND THE SPLINES DONT FIT. There is a lot of bad info out on the Internet on this, including here on this forum. The sad part is that it's people like the Driveshaftshop saying this. They should know better.

im very sorry about this, i was told this was true over and over several times from people here on the board. we will not say it anymore, sorry

[cc-rider]

Originally Posted by Driveshaftshop

im very sorry about this, i was told this was true over and over several times from people here on the board. we will not say it anymore, sorry

No worries. I think your guy's reputation is good and speaks for itself. But I just wanted to clear this up once and for all for everyone. As I pieced this ZL1 swap together, it got a bit frustrating because of all the unknowns. Which is why I started this thread!

[Twoblindsheep]

okay kinda random question but has anyone either swap the gears in the ZL1 Diff? like to 3.91