9.5SF Swap

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OR VietVet

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The G80 in mine performs just fine and I hope it continues. If I ever have a problem in the rear diff I will likely stick with the 3.73 gear but would put a Tru-Trac in it. But all that may be wishful thinking to give me something to do on my Tahoe. Thankfully, with the recently new to me 2005 Fat Boy, I have plenty of crap to remove from it and set it up the way I like 'em. The bolted on goodies that were on there made me cringe when I saw them.
 
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Dantheman1540

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i've beat the "g80" locker in mine pretty good, dont hear about nearly as many failures on the 9.5sf.
the only thing i noticed with mine is it will sometimes engage and not let back off, but thats usually when im doing some tuning or something i'll blast it 0-100 and then immediately make a u-turn i'll noticed the tire want to skip like theyre locked together.

That's good to know. Most of the info I've found for the 9.5 G80 is on pirate 4x4 which Involves 37s or bigger and rocks or mud. I like how the G80 I have now works. Really don't have any complaints so G80 it shall stay. Plus this thing doesn't make much power right now, and likely won't ever make more than 600 to the tire or see slicks.

Tomorrow evening I'll pull the links to compare them to my gmt800 links, hose the thing off and remove the already cut parking brake cable.
 

swathdiver

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Anyone know what diff that is? Clutch style posi?

It's a locking limited slip. Combines the functions of both a locker and limited slip.

From the shop manual:

The optional locking differential (RPO G80) enhances the traction capability of the rear axle by combining the characteristics of a limited-slip differential and the ability of the axle shafts to "lock"together when uneven traction surfaces exist. The differential accomplishes this in 2 ways. First by having a series of clutch plates at each side of the differential case to limit the amount of slippage between each wheel. Second, by using a mechanical locking mechanism to stop the rotation of the right differential side gear, in order to transfer the rotating torque of the wheel without traction to the wheel with traction. Each of these functions occur under different conditions.

Limited-Slip Function

Under normal conditions, when the differential is not locked, a small amount of limited-slip action occurs. The gear separating force developed in the right-hand clutch pack is primarily responsible for this.

The operation of how the limited-slip function of the unit works can be explained when the vehicle makes a right-hand turn. Since the left wheel travels farther than the right wheel, it must rotate faster than the ring gear and differential case assembly. This results in the left axle and left side gear rotating faster than the differential case. The faster rotation of the left-side gear causes the pinion gears to rotate on the pinion shaft. This causes the right-side gear to rotate slower than the differential case.

Although the side gear spreading force produced by the pinion gears compresses the clutch packs, primarily the right side, the friction between the tires and the road surface is sufficient to overcome the friction of the clutch packs. This prevents the side gears from being held to the differential case.

Locking Function

Locking action occurs through the use of some special parts:


  • A governor mechanism with 2 flyweights
  • A latching bracket
  • The left side cam plate and cam side gear
When the wheel-to-wheel speed difference is 100 RPM or more, the flyweights of the governor will fling out and one of them will contact an edge of the latching bracket. This happens because the left cam side gear and cam plate are rotating at a speed different, either slower or faster, than that of the ring gear and differential case assembly. The cam plate has teeth on its outer diameter surface in mesh with teeth on the shaft of the governor.

As the side gear rotates at a speed different than that of the differential case, the shaft of the governor rotates with enough speed to force the flyweights outward against spring tension. One of the flyweights catches its edge on the closest edge of the latching bracket, which is stationary in the differential case. This latching process triggers a chain of events.

When the governor latches, it stops rotating. A small friction clutch inside the governor allows rotation, with resistance, of the governor shaft while one flyweight is held to the differential case through the latching bracket. The purpose of the governor's latching action is to slow the rotation of the cam plate as compared to the cam side gear. This will cause the cam plate to move out of its detent position.

The cam plate normally is held in its detent position by a small wave spring and detent humps resting in matching notches of the cam side gear. At this point, the ramps of the cam plate ride up on the ramps of the cam side gear, and the cam plate compresses the left clutch pack with a self-energizing action.

As the left clutch pack is compressed, it pushes the cam plate and cam side gear slightly toward the right side of the differential case. This movement of the cam side gear pushes the thrust block which compresses the right-hand side gear clutch pack.

At this point, the force of the self-energizing clutches and the side gear separating force combine to hold the side gears to the differential case in the locking stage.

The entire locking process occurs in less than 1 second. The process works with either the left or right wheel spinning, due to the design of the governor and cam mechanism. A torque reversal of any kind will unlatch the governor, causing the cam plate to ride back down to its detent position. Cornering or deceleration during a transmission shift will cause a torque reversal of this type. The differential unit returns to its limited-slip function.

The self-energizing process would not occur if it were not for the action of one of the left clutch discs. This energizing disc provides the holding force of the ramping action to occur. It is the only disc which is splined to the cam plate itself. The other splined discs fit on the cam side gear.

If the rotating speed of the ring gear and differential case assembly is high enough, the latching bracket will pivot due to centrifugal force. This will move the flyweights so that no locking is permitted. During vehicle driving, this happens at approximately 32 km/h (20 mph) and continues at faster speeds.

When comparing the effectiveness of the locking differential, in terms of percent-of-grade capability to open and limited-slip units, the locking differential has nearly 3 times the potential of the limited-slip unit under the same conditions.

Locking Differential Torque-Limiting Disc

The locking differential design was modified in mid-1986 to include a load-limiting feature to reduce the chance of breaking an axle shaft under abusive driving conditions. The number of tangs on the energizing disc in the left-hand clutch pack was reduced allowing these tangs to shear in the event of a high-torque engagement of the differential locking mechanism.

At the time of failure of the load-limiting disc, there will be a loud bang in the rear axle and the differential will operate as a standard differential with some limited-slip action of the clutch packs at low torques.

The service procedure, when the disc tangs shear, involves replacing the left-hand clutch plates and the wave spring. It is also necessary to examine the axle shafts for twisting because at high torques it is possible to not only shear the load-limiting disc, but to also twist the axle shafts.
 
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Dantheman1540

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Holy cow that's a ton of awesome info! That's the stuff you don't get on faceballs.

Just ordered the Spohn lower links hopefully they come this week. Main reason I don't want to order the top links is they have a rod end instead of poly bushings and they typically squeak more. Might take one of the stock links and have one built with poly bushings.
 
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Dantheman1540

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Weather was terrible this weekend but managed to get a little done. Got the links, sway bar, brake lines and parking cable removed. Didn't realize the GMT900 trucks had rear ABS sensors. Ended up cutting the wire at the sensor so water doesn't get in the hole. Also beat the brake heat shields straight again and hit it with some purple power to get it ready for paint this week.
20200405_200742.jpg 20200405_182107.jpg 20200405_195438.jpg 20200405_200731.jpg
 

ls1yukon

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I'veseen some 10bs being passed off as 9.5s as well sneaky ******. I think the gmt800s use a 1320joint not positive. But I already have a built driveshaft so I'll have to look. I'll keep the same gears so throwing a truetrac in should be easy. I think I'll need a different lanyard bar though.

Also the wider width is fine because I have 1/4" spacer on each side and I think 1/2 on each side would be even better.

Probably gonna pull the trigger on this one tomorrow. I'll keep y'all posted

My 2001 came with 3R u-joints. I used the oem shaft, no mod to length, and simply changed the rear u-joint to a 3R to 1350 adapter u-joint. Sorry, I do not recall the part number of the one I used but there are lots available. https://www.bing.com/search?q=3R+to...s=n&sk=&cvid=DD07D37030B94BB387EF07FA59702417
 
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Dantheman1540

Dantheman1540

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My 2001 came with 3R u-joints. I used the oem shaft, no mod to length, and simply changed the rear u-joint to a 3R to 1350 adapter u-joint. Sorry, I do not recall the part number of the one I used but there are lots available. https://www.bing.com/search?q=3R+to...s=n&sk=&cvid=DD07D37030B94BB387EF07FA59702417

Thank you! That's on my list of "to figure outs".

You like to G80 at that power level? I have a similar Magnusson build but it has a Duragrip in a 10bolt and I like it.
I also have a short block laying around I've highly considered making into a 383 for boost.
 

mattt

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Please forgive my ignorance....is this just a beefier axle than our 800's came with? Was this axle ever offered with 3.73 gear from the factory? Just thinking ahead if my 04 Tahoe rear axle currently with 314k miles on it gives up the ghost. A 6.0 I've acquired but haven't dropped in yet may hasten that ghost.
 

OR VietVet

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Please forgive my ignorance....is this just a beefier axle than our 800's came with? Was this axle ever offered with 3.73 gear from the factory? Just thinking ahead if my 04 Tahoe rear axle currently with 314k miles on it gives up the ghost. A 6.0 I've acquired but haven't dropped in yet may hasten that ghost.


When Dan was waxing poetic about this rear diff changeover he was talking about 3.08 gears. I looked at several sites and found the highest gear installed in these diffs was a 3.42. I have 3.73 gars in my diff and this 9.5 ring gear 14 bolt semi-float was my diff I was going to switch to....eventually and stay with the 3.73 gear. I believe if you did this it would help make that diff bullet proof under a Tahoe. I used to belong to a 4x4 club here in Oregon and one of the members put this diff under his Wrangler that was heavily fortified and never broke and he abused the shit out of that 9.5 diff and it never ever failed. I had a 73 Blazer that had a Dana 60 front axle, one ton, and a full float 10.5 ring gear 14 bolt at the back. I truly tried to break but never could. My rig was nicknamed "BRUTUS" for obvious reasons.
 

randeez

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Please forgive my ignorance....is this just a beefier axle than our 800's came with? Was this axle ever offered with 3.73 gear from the factory? Just thinking ahead if my 04 Tahoe rear axle currently with 314k miles on it gives up the ghost. A 6.0 I've acquired but haven't dropped in yet may hasten that ghost.


3.42s is by far the most common, as it came standard behind 6.2/6l80/2WD SUVs - the trucks may have come with them but are all leaf sprung so quite a bit of work would be needed to swap one of them in (gear change would be 100x easier). i came across some weirdly optioned avalanches that these were put in also is about the only application you may find one, but same deal could take forever to find one where as a gear change is a couple hundred bux

the axles are the same width, 6 lug, all the same brake parts fit, all the link arms bolt right in place. its not the end all be all of axles but its a simple swap, the ring gear is 9.5" to the stock 8.5"
 

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