Rearend warranty claim (ATK)

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SRQYukon

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Okay, I need to rant. Jan 2020 I sprang for a reman. rearend for my 2003 Yukon XL form ATK (purchase thru JEGS). Within a few hundred miles, I started having issues with the limited-slip clutches shuddering when making turns. I finally contacted ATK and they shipped a replacement. I've had it for about a month and we finally got around to swapping it. I reserved my son-in-law's shop and lift (and master mechanic skills), to do the swap today. Right out of the crate, we notice that the left UCA bracket is bent about 4 or 5° out-of-square with the diff. We debated and decided to proceed with trying to straighten it. After about an hour of experimenting, we ended up heating the bracket with a torch and beat the snot out of it with a 5 lb hammer. We got it reshaped and proceeded. Then we have some issues with the right rear rotor and caliper not aligning correctly. Upon closer examination, we noticed that the brake bracket is seriously bent. So much so, that the caliper dragged on the outer edge of the rotor (probably about 1/4" out). We ended up having to remove the rear axles from both units, swap the brake mounting plate, and then reassemble the diff., axle, and brakes. Of course, that means drain all of the brand new gear oil limited-slip additives and trying to save it. So a two-hour swap took six hours, in all. It was very obvious that the truck this came out of took a hard hit on the driver's side, bent the UCA bracket and the brake backer bracket on the opposing. Shame on ATK for not inspecting the cores before rebuilding them. It is so obvious that no one on their reman. line cares. The UCA bracket was so tweaked, I noticed it the second we opened the crate. This means that all of the people that touched this thing ignored the damage, including whoever crated it. So, if you're considering buying from ATK, maybe you'd better reconsider.
IMG_3308.JPGIMG_3309.JPGIMG_3319.JPGIMG_3321.JPGIMG_3322.JPG
 

Bill 1960

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9.9 on the rant. Had to deduct a tenth for no paragraphs LOL.

Yeah, I’d be pissed about that too. Damned if you fix their screwup and damned if you do a return.
 

swathdiver

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Okay, I need to rant. Jan 2020 I sprang for a reman. rearend for my 2003 Yukon XL form ATK (purchase thru JEGS). Within a few hundred miles, I started having issues with the limited-slip clutches shuddering when making turns. I finally contacted ATK and they shipped a replacement. I've had it for about a month and we finally got around to swapping it. I reserved my son-in-law's shop and lift (and master mechanic skills), to do the swap today. Right out of the crate, we notice that the left UCA bracket is bent about 4 or 5° out-of-square with the diff. We debated and decided to proceed with trying to straighten it. After about an hour of experimenting, we ended up heating the bracket with a torch and beat the snot out of it with a 5 lb hammer. We got it reshaped and proceeded. Then we have some issues with the right rear rotor and caliper not aligning correctly. Upon closer examination, we noticed that the brake bracket is seriously bent. So much so, that the caliper dragged on the outer edge of the rotor (probably about 1/4" out). We ended up having to remove the rear axles from both units, swap the brake mounting plate, and then reassemble the diff., axle, and brakes. Of course, that means drain all of the brand new gear oil limited-slip additives and trying to save it. So a two-hour swap took six hours, in all. It was very obvious that the truck this came out of took a hard hit on the driver's side, bent the UCA bracket and the brake backer bracket on the opposing. Shame on ATK for not inspecting the cores before rebuilding them. It is so obvious that no one on their reman. line cares. The UCA bracket was so tweaked, I noticed it the second we opened the crate. This means that all of the people that touched this thing ignored the damage, including whoever crated it. So, if you're considering buying from ATK, maybe you'd better reconsider.
View attachment 347032View attachment 347033View attachment 347034View attachment 347035View attachment 347036
These trucks don't have limited slip rear differentials and do not require the additive. The additive makes the rear chatter even.
 

rockola1971

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These trucks don't have limited slip rear differentials and do not require the additive. The additive makes the rear chatter even.
Ive never dug into the codes for the tahoe but i do know that my 99 (OBS) GMC Sierra Z71 had a limited slip locking differential so it had clutches ("Hockeypucks") and required the addditive to prevent chatter. Had to dig in deep on that one because it was not locking and made a hell of a racket. CLutches were toast and me and the BIL rebuiilt it on a Saturday along with all bearings and races. Had a drivers side axle bearing been whining for years when you let off the throttle.
 

rockola1971

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Okay, I need to rant. Jan 2020 I sprang for a reman. rearend for my 2003 Yukon XL form ATK (purchase thru JEGS). Within a few hundred miles, I started having issues with the limited-slip clutches shuddering when making turns. I finally contacted ATK and they shipped a replacement. I've had it for about a month and we finally got around to swapping it. I reserved my son-in-law's shop and lift (and master mechanic skills), to do the swap today. Right out of the crate, we notice that the left UCA bracket is bent about 4 or 5° out-of-square with the diff. We debated and decided to proceed with trying to straighten it. After about an hour of experimenting, we ended up heating the bracket with a torch and beat the snot out of it with a 5 lb hammer. We got it reshaped and proceeded. Then we have some issues with the right rear rotor and caliper not aligning correctly. Upon closer examination, we noticed that the brake bracket is seriously bent. So much so, that the caliper dragged on the outer edge of the rotor (probably about 1/4" out). We ended up having to remove the rear axles from both units, swap the brake mounting plate, and then reassemble the diff., axle, and brakes. Of course, that means drain all of the brand new gear oil limited-slip additives and trying to save it. So a two-hour swap took six hours, in all. It was very obvious that the truck this came out of took a hard hit on the driver's side, bent the UCA bracket and the brake backer bracket on the opposing. Shame on ATK for not inspecting the cores before rebuilding them. It is so obvious that no one on their reman. line cares. The UCA bracket was so tweaked, I noticed it the second we opened the crate. This means that all of the people that touched this thing ignored the damage, including whoever crated it. So, if you're considering buying from ATK, maybe you'd better reconsider.
Thats ALOT of tweaks to the steel of the rear axle! Obvious wreck damage there unless ATK dropped the axle form 20ft, 30 times! Excellent rework of the metal. You guys did a fine job there. Looks like a factory new piece.
 

swathdiver

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Ive never dug into the codes for the tahoe but i do know that my 99 (OBS) GMC Sierra Z71 had a limited slip locking differential so it had clutches ("Hockeypucks") and required the addditive to prevent chatter. Had to dig in deep on that one because it was not locking and made a hell of a racket. CLutches were toast and me and the BIL rebuiilt it on a Saturday along with all bearings and races. Had a drivers side axle bearing been whining for years when you let off the throttle.
You're right, technically it is a locking limited slip and the 800s and 900s do not require the additive. GM still calls it a G80. However, the G80 in my Buick was a true limited slip but the G80 in trucks is a different animal.
 
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SRQYukon

SRQYukon

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These trucks don't have limited slip rear differentials and do not require the additive. The additive makes the rear chatter even.
These trucks don't have limited slip rear differentials and do not require the additive. The additive makes the rear chatter even.
So you're saying this is not a Posi-traction rearend at all? Or is it just not limited slip? So what does the G80 code really mean?
 

swathdiver

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So you're saying this is not a Posi-traction rearend at all? Or is it just not limited slip? So what does the G80 code really mean?
Let me post for you the description from the shop manual for a better, more clear, explanation than I can:

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 righthand
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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SRQYukon

SRQYukon

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Man, Swathdiver, you know your stuff. So I need to be sure that when the lube is changed after 500 miles, that NO limited-slip additive is used. Thanks for the detailed explanation.
 
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SRQYukon

SRQYukon

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So this problem with the ATK/LQK G80 differential has resurfaced with my 2003 Yukon XL. Here's the history in chronological order:

Dec 2019: ordered reman g80/GT4 differential from Jegs (ATK reman)
Jan 2020: Had my mechanic install the diff
Mid-Jan 2020: Went through the break-in process and returned to have the fluid changed using OEM synthetic 75w90 lube. Within a few days, the differential started to have chatter when turning (when cold or cool, not when at operating temp). The problem persisted and the mechanic decided to add friction modifier additive to see if it made a difference. No change. We drained the lube again and put in the 75w90 Amsoil Severe Gear which has the GL-5 cert. No change in the chatter except that it worsened over time.
Feb 2021: Contacted ATK/LKQ warranty and discussed my issue. They agreed to send a replacement differential and cover some of the installation expenses.
April-July 2021: Received the replacement unit in April, but had other suspension and brake work to do so put off installation until July.
July 2021: Installed replacement differential and went through the break-in process. At 600 miles. went in for a lube change. My mechanic changed the lube with Amsoil 75w90 Severe Gear Synthetic lube with no friction modifier. Exact same results as before. Chatter started within days and has now become worse. This only occurs when the truck sits overnight or for several hours. Never any chatter when the lube gets hot.

I'm at a loss for what to do now. This has cost me a fortune in repairs and downtime and I'm no closer to resolution. It appears clear to me that whatever lube ATK puts in before shipping out the unit and the lube that my mechanic is using are different. What is confusing is that we have tried both the GM synthetic 75w90 and the Amsoil 75w90, and the GM synthetic with additional friction modifier, and nothing makes any difference.

Please, if anyone out there has experience with this problem, I would love to hear from you if you have a solution. I'm willing to try anything that seems reasonable. However, if you read the earlier posts you will see that several have already provided information such as the manual lube specs and service bulletins. NONE OF THIS HAS WORKED. Right now I'm running the Amsoil Severe Gear Synthetic lube with no modifier at the diff chatters like crazy every morning until the lube gets warm.
 

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