How to bulletproof a Chevy C5 Corvette for track d...

Bulletproofing the Clutch

Inventory C5 Corvette Z06 clutches needs to be filed beneath “barely satisfactory.” Our inventory clutch was advantageous for avenue responsibility–again when it was doing such issues–however even heavy autocross use with the inventory engine began to trigger points. Warmth would result in slippage, which might result in extra warmth, and the cycle would spiral till we simply wanted to let the factor cool again to ambient.

We initially changed the inventory clutch with a stronger, single-disc unit. Whereas we had been swapping engines, nevertheless, we determined to go all the way in which and improve to a twin-disc unit from Mantic Clutch USA coupled to an aluminum flywheel. This utterly rebuildable clutch is rated for greater than 1000 lb.-ft. of torque and options titanium drive blocks that additional cut back rotating mass. 

[Project Corvette Z06: Why a Multi-Disc Clutch Saves Weight While Increasing Clamp Load]

Our twin-disc setup additionally weighs 32 kilos, 6 kilos lower than the single-disc unit it changed and 23 kilos lower than the inventory setup. Retail is about $2750, however we really spent extra on that single-disc clutch. 

Images Credit score: J.G. Pasterjak

Specs on paper are one factor, however the true check can be its operation and longevity in excessive circumstances. Operationally, we couldn’t be extra delighted. The motion of the clutch pedal feels similar to–probably even lighter than–the inventory setup. It’s easy and intuitive, and the chew level is simple to choose up for constant launches. Briefly, we hardly give it some thought, which is a number of the highest reward we are able to heap on a clutch.

As for its longevity, time will inform, however Mantic Clutch USA’s Geoff Gerko shared some greatest practices. Warmth is its largest enemy, he stresses: “Don’t slip the clutch any greater than essential. Get it rolling within the pits and get that clutch utterly engaged as fast as you’ll be able to when idling round. Push it on to scales, winch it onto the trailer, and make these upshifts and downshifts rapidly and positively, and also you’ll defer any pointless put on for a very long time.” 

He provides that lack of exercise might result in accelerated put on: “Don’t let it sit for months at a time with out at the least taking a drive to get some warmth and friction into it to maintain the mating surfaces completely happy.” 

So long as the clutch feels good, Gerko concludes, there isn’t a lot want for normal inspection. “Should you pull it aside for inspection, you really threat contaminating the discs and friction surfaces,” he says, “so it’s greatest to only let it maintain doing what it’s doing till it’s time to rebuild.”

Bulletproofing the Torque Tube

As an alternative of linking the engine to the rear-mounted transmission with a standard driveshaft, the C5 does it with a torque tube. We had ours utterly rebuilt after we carried out our first clutch swap. The Vette Physician in Melbourne, Florida, used OEM components from entrance to rear, together with new bearings, seals and driveshaft couplers. 

We didn’t improve to aftermarket couplers, however our originals nonetheless regarded good upon inspection. Maybe these inventory, thick rubber couplers, which damp driveline vibration each for passenger compartment NVH attenuation and mitigating part fatigue, are simply advantageous for observe use. 

See these cracks within the torque tube’s drive coupler? (Don’t fear, it’s not ours.) It’s a standard put on merchandise in C5 Corvettes. Luckily, factory-fresh ones appear to work effectively on observe–you simply have to repeatedly examine them. Images Credit: J.G. Pasterjak

An off-the-cuff ballot of C5 house owners backs up our findings. The inventory drive couplers–assuming they’re in fine condition–appear to have loads of extra capability to deal with extra energy and torque. Plus, “upgraded” couplers–ones made from stiffer urethane and even stable supplies like aluminum–nonetheless fail at about the identical charge as inventory items whereas introducing second-order problems within the type of extra vibrations.

So, are all aftermarket couplers junk? In all probability not, however we aren’t fearful about untimely failure based mostly on what we’ve seen and heard. Ought to we attain the purpose the place we have to improve, we would transfer to OEM items from a Corvette ZR1–a preferred improve for many who need some extra insurance coverage however need to keep inside the GM components catalog.

Bulletproofing the Gears

Did we have to fear concerning the additional energy tearing up our transmission? We checked in with GearFX, the agency that initially rebuilt and optimized our field. 

[Project Z06: Polishing the Internals of Our Transmission]

GearFX’s Jeff Horton confirmed us some testing carried out by REM Floor Engineering, the corporate whose expertise GearFX makes use of to shine and prep the important thing surfaces of the transmission. Funds about $500 for related therapy. 

REM’s testing confirmed that its sharpening course of elevated sturdiness by 100%. Credit score goes to diminished friction, fewer stress risers, and the related advantages of the micropolished surfaces. Parts that sometimes skilled a 90% failure charge after 200 million check cycles persistently wanted as many as half a billion cycles to supply an analogous failure charge after the REM sharpening course of. 

GearFX ran our gears by way of the REM-polishing course of. Excessive-tech abrasives are used to shine steel elements and cut back friction-induced warmth and stress risers.

Nonetheless, you’ll be able to’t REM each floor inside a transmission, and Horton says the largest put on gadgets will nonetheless be issues the driving force controls. “The world that REM doesn’t have an effect on or assistance is driver-induced synchro put on,” he notes. “The gear tooth and shafts will probably be stronger, however the synchro tooth are nonetheless a sufferer of the driving force, though we put in upgraded synchros. Since we REMed the shifting finger and guides, it is going to be a smoother shift, nevertheless I’ve been round lengthy sufficient to know that some guys can put on out something.” 

Our mission going ahead is to train some mechanical empathy. We have to find out how rapidly we are able to shift with out beating the synchros and inflicting untimely put on. Shifting too slowly may be simply as detrimental at greater hundreds, because it offers the engine extra time to drop revs and induce extra driveline shock as soon as the shift is accomplished. Follow makes excellent. 

Except for these cautions, Horton says, upkeep needs to be precisely the identical as every other track-used automotive. Meaning common fluid checks and adjustments–we use artificial GM Dexron VI ATF. Except for that, don’t contact it until one thing goes flawed.

Bulletproofing the Drivetrain Mounts

Even with the inventory authentic engine, we’d begun experiencing a whole lot of wheel hop on launches–and even beneath rolling acceleration in decrease gears. 

We traced the difficulty to a failing differential mount–a single, center-mounted, versatile connection much more involved with occupant consolation than energy transmission. It did a awful job of retaining that relationship constant, permitting the differential to rotate in a aircraft perpendicular to the driveshaft. And because it was undamped, it become an oscillating spring as soon as pressure was utilized. 

Our answer got here from aFe Energy within the type of the model’s Pfadt differential mount–about $500 retail. This billet aluminum mount options outriggers that extra successfully switch torque to the subframe whereas higher supporting the differential by way of each leverage and stiffer urethane and metallic mounts. 

Images Credit: aFe Energy (prime, second from prime), J.G. Pasterjak

Set up took only some minutes, and adjustment of the outrigger pads took only some extra minutes. The advantages had been instantaneous and gorgeous: no extra wheel hop, predictable torque supply, zero worries.

We changed our engine mounts with aFe Energy models as effectively, and we suggest the identical for anybody doing the diff mount improve. Should you’re putting in headers or a dry sump, you’ll have to improve these engine mounts from inventory, because the OEM items received’t present sufficient clearance.

Onerous launches on grippy concrete with sticky tires produce a whole lot of driveline pressure. Correctly coping with that pressure will increase each efficiency and reliability. The OEM diff mount–that comfortable factor on the prime of the web page–acts like a giant, floppy, rubber pillow, however the aFe unit options stiffer building because of extra leverage and decreased flex. Set up is easy, however you may lose somewhat knuckle pores and skin. It’s value it, although. We additionally changed our inventory engine mounts–the black rubber issues to the left–with stiffer ones from aFe Energy. Images Credit score: Wayne Presley

Bulletproofing the rear finish

Further energy may be brutal on the rear finish, however GearFX had already future-proofed ours when it put in a REM-polished ring and pinion in addition to a torque-biasing WaveTrac differential. Upkeep right here ought to simply contain common fluid checks and adjustments. The sharpening and blueprinting course of significantly cuts down on steel filings suspended within the fluid, additional decreasing put on. 

Wavetrac affords a drop-in answer for the C5 Corvette’s inventory, clutch-based differential. Whereas many gear-driven diffs can open absolutely when one wheel utterly unloads, Wavetrac defeats this tendency with its proprietary wave ramp system that may lock collectively the pushed wheels. Images Credit: J.G. Pasterjak (differential), Courtesy Wavetrac (illustration)

As really helpful by GearFX, we broke in our gears on some Pushed Racing Oil rear-end break-in lube. After some miles and warmth cycles, we converted to Motul 75W-90 artificial gear oil. This fluid doesn’t have a limited-slip additive, because the WaveTrac diff derives its limited-slip properties from gears, not clutches.

These diffs want correct lubrication; we’re operating Motul Gear 300. Images Credit score: J.G. Pasterjak

The WaveTrac can require a change in driving fashion, nevertheless. For some recommendation right here we reached out to our good friend, former professional racer Jason Saini, who’s had expertise with nearly each sort of diff. 

Saini says gear-driven diffs like our WaveTrac are extraordinarily forgiving and easy. “The quantity of lock is decided by the quantity of slip that occurs,” he explains. “In order slip will increase, the worm gears counteract that and switch torque to the wheel with extra traction in a really linear vogue. This occurs each in acceleration and deceleration, so a gear-style diff tends to be very predictable and intuitive.” 

However there are a number of problems, he continues. “The system does require some resistance to operate. So if a wheel turns into utterly unloaded, you will get something from inside wheelspin to unpredictable habits based mostly on how the producer of the diff set it up. 

“There’s additionally no actual adjustability like there’s with a clutch or ramp diff, the place you’ll be able to alter the lockup and unlock by way of totally different clutch plates, springs or ramps. However the cool factor there’s the way in which the gear diff is continually reacting to traction situations in actual time. If the producer did their homework with gear angles, you shouldn’t have to make any changes.”

Saini’s backside line on torque-biasing diffs: “Simply get pleasure from them, as a result of they’re simple to drive with and predictable. Should you’re getting right into a scenario the place you’re utterly unloading a wheel and experiencing unpredictable habits, begin roll stiffness with springs and sway bars and do what you’ll be able to to maintain that inside wheel loaded sufficient to maintain the diff functioning.”

Bulletproofing the Hubs

Hubs are missed workhorses. They solely, , maintain the wheels to the automotive. In almost three years of observe and autocross use, we by no means wanted a hub improve or alternative. 

However then we threw almost 100 extra horsepower on the floor and mounted some sticky tires, and instantly we had been going by way of hubs like they had been bottomless chips and salsa at Chili’s. The rear hubs appeared to bear the brunt of the elevated load, repeatedly displaying telltale slop when rocked in a vertical aircraft, however we additionally snapped a flange utterly off a entrance hub.

[How to upgrade wheel hubs | Project C5 Corvette Z06]

We first tried to “lower your expenses” by skipping the full-race hubs and sticking with OE-style components–to the tune of $130 to $260 every relying on model, provider and time of 12 months. In any case, we reasoned, we often solely run a number of laps at a time, and the stock-type components value a lot much less.

Nope.

“Effectively, actually we are able to get by with these ‘premium’ variations of the off-the-shelf hubs,” was our subsequent rationale. “They solely value a number of {dollars} extra, however [insert fallacious reasoning here].”

Nope, however louder.

Crap.

Ethical of the story: Purchase the nice hubs. We must always have bitten the bullet up entrance, however as a substitute we received nickel-and-dimed by inferior merchandise that lasted as few as 20 autocross runs and a few dozen observe laps. 

Inventory-grade Corvette hubs aren’t as much as the duty of arduous observe driving. The answer is SKF X-Tracker hubs, identifiable by their black oxide end. They might appear dear, however you get what you pay for.  Take a look at our YouTube web page for the step-by-step. Images Credit: J.G. Pasterjak

The “good hubs” on this painful lesson are SKF X-Trackers, and we sourced ours from Sam Strano at Stranoparts. With a avenue worth round $400 every as of press time (costs have been fluctuating quite a bit currently due to provide chain points), the X-Trackers are “purchase as soon as, cry as soon as” gadgets. In all our calling round, we by no means discovered a Corvette proprietor whose X-Trackers failed as a result of something wanting a crash. That’s a heck of quite a bit worse than 20 autocross runs and some sizzling laps.

Accoding to SKF, the X-Trackers, which can be found for a wide range of purposes and are even used as OEM items on some manufacturing unit hotrods, improve sturdiness by way of optimized design and supplies to withstand deflection between the fastened and rotating parts of the hub. Even minute deflections within the hub meeting result in warmth spikes as a result of localized areas of elevated friction, and warmth plus stress is as certain a killer as a weight loss plan of doughnuts and PCP. 

That deflection may result in second-order results like elevated brake pad knockback, particularly when fixed-position calipers are additionally getting used. Tiny bodily deflections on the hub face are magnified on the outer diameter of the rotor and may work the pistons again into the calipers, leading to a low pedal. Yeah, we had a few of that, too.

Luckily, putting in hubs on a C5 is easy–see our YouTube channel for a whole step-by-step. Lengthy story quick, you’ll have to take away the brake caliper, decrease ball joint and tie rod to disconnect the upright so it might swing out far sufficient to succeed in the bolts securing the hub meeting to the upright. Within the rear, you’ll additionally have to take away the axle nut and slide the axle out of the hub. We received to the place we might do all 4 in lower than 90 minutes. We want we’d by no means gotten the prospect to get that good at it.