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How do you remove the backlash from a G80 differential?

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  • Chevrolet Master
  • 2,019 Answers

You never want to remove it completely.
There is supposed to .006 to .010" backlash.

Assuming you have removed the CV joints and seals, and the pinion is at the right depth, etc., then you turn the threaded adjuster rings on both sides, in order to move the ring gear closer or further from the pinion.
The distance between them should not change, so if you move the left on in, you need to move the right one out the same fraction of a turn or more.
To be sure of a good mesh, apply prussian blue to the pinion and watch the transfer marks to see they are centered and full length.

More detail here:
http://www.gmfullsize.com/forum/showthread.php?t=16111&highlight=setting+backlash+on+ifs

But make sure no bearing is going bad first, because then trying to adjust anything will only make it worse. Check endplay on pinion.

Posted on Sep 13, 2010

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What is the torque spec for a 1978 Ford pinto differential pinion nut?


170 ft.lbs is the minimum; be aware that this differential uses a crush sleeve to set the backlash and the pinion torque is what crushes the crush sleeve. If you don't set the backlash correctly you can grind up your differential gears.
8 Inch Ford Rear End Torque Specifications eHow

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WHY DOES MY 2004 BUICK RAINIER'S REAR END GRAB WHEN TURNING ?


GM TSB#PIP4045A
NHTSA ID#10024345
Summary: EATON LOCKING DIFFERENTIAL CHATTER SHUDDER NOISE ON TURNS, EQUIPPED WITH A LOCKING REAR DIFFERENTIAL RPO G80. *NJ UPDATED 7/17/2008. *PE
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02 Silverado G80 differential is not locking according to the g code in my glove box I have a G80 differential but I have had my truck spining tires on road and off road my differential dose not lock in...


remove differential cover and rotate carrier look in the area around the axle gear small teeth can be seen with little gears that come to a flywheel weight governor (g80) that spins and tightens the axle gears against the carrier creating posi. works only under power

Jun 10, 2014 | Cars & Trucks

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My 2002 dodge 1500 has 392 rear end gears iwhant 353 gears what do ido


you can remove the axles and the drive shaft then open the differential to remove the carrier gear assembly(ring gear,side gears)then remove the pinion gear.replace these with the new gear set and get the clearance specs for the pinion depth and carrier gear clearance and adjust until within specs.you can either pickup new gear sets or one from the wreckers with the shims to start with.you will need a backlash dial gage to know if the backlash clearance is within specs as well as marking ink to know if the gear mating surface is riding in the proper area of contact.

Jul 11, 2011 | 2006 Dodge Ram 2500

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Want to change gears in rear end for posi traction in a 98 gmc25000 is this possible?


It is possible, you just have to know what gear ratio you have in your Sierra. I had issues with my son's rear differential and did the Salvage Yard and picked one up for $250.00 with less then 45,000 miles. Remember new cars end up at Salvage Yards also.

Here are the Pro code for the rear ends to your Sierra and you can match one up at a Salvage Yard.
GQ1 -- AXLE REAR, STD RATIO
GT4 -- AXLE REAR, 3.73 RATIO
GT5 -- AXLE REAR, 4.10 RATIO
GU4 -- AXLE REAR, 3.08 RATIO
GU5 -- AXLE REAR, 3.23 RATIO
GU6 -- AXLE REAR, 3.42 RATIO
G80 -- AXLE REAR, LIMITED SLIP (POSI TRACTION)

HC4 -- AXLE REAR, 4.56 RATIO

Open Your glove box and look inside it. Should be a list of codes on the bottom.
Example: GU6 G80 According to that, you'll have a 3.42 posi

Good luck and keep me posted and call around Salvage Yards, there prices will differ from one to the next salvage yard and don't ask them for a posi rear end. The cost will you more, just search all the SUV's and look at the pro codes in the glove box. Hunt, most awd system SUV will have the G80 rear end.

Good luck and keep me posted.

Jan 10, 2010 | 1993 GMC Sierra K1500

1 Answer

Can the gears be changed from 4.11 to 3.7 w/o changing rear end?


Yes, you can leave the axle housing installed, but you will have to pull the axle shafts. You will likely have to purchase a specialty tool to do this.

(If you have the massive drums found on the 3500s and some 2500's, this would also be a good time to re-grease your bearings and check your rear brake shoes and change them if worn beyond 50%, since you will have the axle ends taken apart. These drums are very heavy. Do not remove the trapped bearing from the drum.)

To go from 4:11 to 3:73, You only need to swap out the gears in the differential (including the pinion gear) Be sure to check for proper alignment and backlash. Re-install axle shafts. Replace, do not reuse any seals. You may also need to reprogram the trucks shift points for the new gear ratio to maximize efficiency results.

Note: By changing your gear ratio to 3:73 You may potentially decrease your trucks Towing/Hauling weight capacity. Many GM trucks are equipped with an Eaton mechanically locking rear (RPO code: G80). You can find out if yours is so equipped, by checking the label inside the glove box. Personally I prefer the G80.

(I have the 3:73s in My '97 C2500 and average around 10.5MPG city, but long freeway runs can hit 15+MPG. My GVW is 8600LBS, and 10,000LBS Towing capacity. "Stop & Go" driving is your worst enemy with these trucks.)

Consider if all the work involved is worth it in performance gains before going forward.

Nov 16, 2009 | 1996 Chevrolet K2500

1 Answer

Pinion nut torque spec chev


Axle Preload and Backlash Specifications 8.0 Axle Preload and Backlash Specifications Application
Specification
Metric
English
Backlash
0.08-0.25 mm
0.003-0.010 in
Backlash (Preferred)
0.13-0.18 mm
0.005-0.007 in
Pinion Bearing Preload, New Bearings
1.7-3.4 N·m
15-30 lb in
Pinion Bearing Preload, Used Bearings
1.1-2.3 N·m
10-20 lb in
Pinion and Differential Case Bearing Preload, New Bearings
3.4-6.2 N·m
30-55 lb in
Pinion and Differential Case Bearing Preload, Used Bearings
2.8-5.1 N·m
25-45 lb in

May 17, 2009 | 2006 Chevrolet Colorado

1 Answer

Want to install a posi unit in my 2004 Ram Quad 2WD 9.25


REMOVAL
  1. Remove filler plug from the differential cover.
  2. Remove differential cover and drain the lubricant.
  3. Clean housing cavity with flushing oil, light engine oil or a lint free cloth. NOTE: Do not use steam, kerosene or gasoline to clean the housing.
  4. Remove axle shafts.
  5. Remove RWAL/ABS sensor from housing. NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
  6. Mark differential housing and bearing caps for installation reference (REFERENCE MARKS).
  7. Remove bearing threaded adjuster lock from each bearing cap.
  8. Loosen differential bearing cap bolts.
  9. Loosen differential bearing adjusters through the axle tubes with Wrench C-4164 (THREADED ADJUSTER TOOL).
  10. Hold differential case while removing bearing caps and adjusters.
  11. Remove differential case. NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.

INSTALLATION
  1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position.
  2. Install differential assembly into the housing.
  3. Install differential bearing caps in their original locations (BEARING CAPS).
  4. Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated.
  5. Perform the differential bearing preload and adjustment procedure. NOTE: Be sure that all bearing cap bolts are tightened to their final torque of 136 N·m (100 ft.lbs.) before proceeding.
  6. Install axle shafts.
  7. Apply a bead of orange Mopar Axle RTV Sealant or equivalent to the housing cover (COVER SEALANT). CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
  8. Install the cover and any identification tag and tighten cover bolts to 41 N·m (30 ft. lbs.).
  9. Fill differential with lubricant to bottom of the fill plug hole. Refer to the Lubricant Specifications for the correct quantity and type. NOTE: Trac-lok™ differential equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint.
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing preload and gear backlash:
  • The maximum ring gear backlash variation is 0.076 mm (0.003 in.).
  • Mark the gears so the same teeth are meshed during all backlash measurements.
  • Maintain the torque while adjusting the bearing preload and ring gear backlash.
  • Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise.
  • Insufficient adjuster torque will not support the ring gear correctly and can cause excessive differential case free-play and ring gear noise.
NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments:
  • Maintain the gear teeth engaged (meshed) as marked.
  • The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth.
  • Do this five to ten times each time the threaded adjusters are adjusted.

  1. Through the axle tube use Wrench C-4164 to adjust each threaded adjuster inward until the differential bearing free-play is eliminated. Allow some ring gear backlash approximately 0.25 mm (0.01 in.) between the ring and pinion gear. Seat the bearing cups with the procedure described above.
  2. Install dial indicator and position the plunger against the drive side of a ring gear tooth (RING GEAR BACKLASH). Measure the backlash at 4 positions, 90 degrees apart around the ring gear. Locate and mark the area of minimum backlash.
  3. Rotate the ring gear to the position of the least backlash. Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed.
  4. Loosen the right-side, tighten the left-side threaded adjuster. Obtain backlash of 0.076 to 0.102 mm (0.003-0.004 in.) with each adjuster tightened to 14 N·m (10 ft. lbs.). Seat the bearing cups with the procedure described above.
  5. Tighten the differential bearing cap bolts 136 N·m (100 ft. lbs.).
  6. Tighten the right-side threaded adjuster to 102 N·m (75 ft. lbs.). Seat the bearing cups with the procedure described above. Continue to tighten the right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft. lbs.)
  7. Measure the ring gear backlash. The range of backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).
  8. Continue increasing the torque at the right-side threaded adjuster until the specified backlash is obtained. NOTE: The left-side threaded adjuster torque should have approximately 102 N·m (75 ft. lbs.). If the torque is considerably less, the complete adjustment procedure must be repeated.
  9. Tighten the left-side threaded adjuster until 102 N·m (75 ft. lbs.) torque is indicated. Seat the bearing rollers with the procedure described above. Do this until the torque remains constant.
  10. Install the threaded adjuster locks and tighten the lock screws to 10 N·m (90 in. lbs.).

Jan 14, 2009 | 2004 Dodge Ram 1500

1 Answer

Diff noise


I can understand on accel. and turning but decel I have never seen that I think it's possible tho. too much backlash would make sense

Sep 10, 2008 | 1996 Chevrolet Corvette

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