Did the install work today for new cast iron front locker. Reloader was able to assemble the CI diff this week using the new parts plus parts scavenged off of a spare diff in the garage.
We reused:
- Diff cover
- Axle tube
- Yoke
- Passenger's side diff mount plate as it was from PCF. I upgraded the driver's side at this time. (Only passenger side had been replaced as it was the prototype for the upgrades that he offers now).
New parts:
- Cast Iron differential housing 25831502 ~$400
- Eaton locker, OEM 25800300 ~$540
- Bearing kit, USA Gear. USA Standard Gear (ZK GM7.5-A) Master Overhaul Kit for GM 7.5" Differential $60 (incorrect pinion bearings included. Look for a 7.625 IFS bearing kit if you want kit with correct pinion bearings)
- Outer pinion bearing 9417784 $39
- Inner pinion bearing 22510042 $35
- Pinion bearing crush sleeve $13 (included in USA Gear kit)
- Breather connector 15876530 $8
- Drain plug (can be reused from alum diff) 92230583 $12
- Front differential pinion seal 12479267 $13
- Yukon ring and pinion, (YG GM7.5-456) High Performance Ring and Pinion Gear Set for GM 7.5" Differential $261
- Bracket 25933550 $3
- Side axle bearings
Since we were doing this work, it gave us easy access to the motor mounts. This is mount #5 on the passenger side, #3 on the driver's side. The driver's one didn't need it yet, and the passenger side was just a few miles away from failing.
I also put in the PCF diff support, as mentioned
We drained the old diff and found good shavings on it. After we pulled the diff, we found that the ring gear was badly damaged on three teeth.
Also found out that the driver's side wheel bearing was shot. The passenger one isn't far behind. These are the original bearings with 174,000 miles on them
[video=youtube_share;gXhClgMJXYw]https://youtu.be/gXhClgMJXYw[/video]
We decided to do the rear brake pads too but realized the rear wheels were not spinning smoothly, so we drained the oil from the diff. The drain plugs should not look like this. This appeared to have "normal" locker shavings but also more than that.
We removed the rear diff cover and found this chunk underneath about the size of a large molar
Here's the side gears that are missing teeth AND broken into two pieces
There's a dent in the cover that suggests that pieces tried to evacuate themselves through the cover at some point.
So, now it's time to completely rebuild the rear end: new ring and pinion, carrier bearings, entire locker assembly, axle seals, etc. It's undriveable until then.