Originally Posted by 83GMCK2500 (Post 6328081)

Great thinking on those hubs. I know the "gasket" that GM uses is a thin steel shim that rarely seals in my experience, even with a little ultra black. Smoothing them off like that should really help with sealing.

Originally Posted by ryanroo (Post 6328182)

people say a lot of bad stuff about the G80. i dont think you will ever find cause to complain. they work pretty darn good in a stock truck with a driver that doesn't beat on the truck like a high school idiot.

they will spin just a bit and then lock in, to a fully locked differential. i've had them in in several trucks with the 14bff. nary an issue. in my big, beat it like you stole it offroad jeep, i went with a detroit to avoid any issues that may or may not have arose from the lock in while doing something abusive. and detroits are really simple without the complexity of the G80. good news is that the G80 doesnt require any special additives like a clutch type limited slip

Originally Posted by Tx Firefighter (Post 6328115)

Devin,

First, I wanted to say I spun the gear carrier and counted 3 pins so I guess I have a Gov-Loc. I've heard a lot of unflattering stuff about them, but never really paid attention very closely to the details.

As far as the gaskets, I got these from Rockauto. They were like 2 bucks each. I figure I'll smear them with a real thin layer of number 2 Permatex. I've always done it that way and haven't ever had a leaker. Lets hope it works this time.

http://i276.photobucket.com/albums/k...psce43d8a1.jpg

I'm kind of geeking out on this stuff I know. It seems the number of participants on this thread has dwindled. I guess the details are a bit tedious and boring. When I'm done I should have a clean black rearend, black hubs and drums and all new shiny plated hardware to make the details pop.

Originally Posted by GM

LOCKING DIFFERENTIAL LUBRICANT (SERVICE INFORMATION) #91-4-109
SUBJECT: LOCKING DIFFERENTIAL (G80) LUBRICANT - (SERVICE INFORMATION)
VEHICLES AFFECTED: ALL LIGHT TRUCKS EQUIPPED WITH G80 REAR AXLE ALL YEARS
Some light duty trucks equipped with locking rear axles (G80) may exhibit rear axle chatter, especially when turning a corner from a stop.
This condition of alternate engagement and disengagement of clutches in differential assembly is usually caused by contaminated axle lubricant.
To correct this condition, drain and refill the rear axle with SAE 80W-90 GL5 (P/N 10950849).

The use of any additive in locking rear axles (G80) is not recommended. Rear axle additives are designed for use in limited slip differentials which are normally installed in cars. All light duty trucks equipped with RPO G80 make use of a locking differential and the use of additives will delay the engagement of the locking mechanism and may decrease axle life.

VEHICLES/COMPONENTS INVOLVED: ------------------------- ---- Some light duty trucks equipped with locking rear axles, RPO G80.
SERVICE PARTS INFORMATION:
Part Number Description ----------- ------------------ 10950849 Lubricant, Rear Axle (1 litre)
Parts are currently available through CANSPO.
WARRANTY INFORMATION:
As specified in Light Duty Truck Maintenance Schedules, locking rear axle fluid drain and refill is required owner maintenance at the first engine oil change. Failure to drain and refill the rear axle as specified may contribute to a later axle chatter condition. Refer to the appropriate Light Duty Truck Maintenance Schedule or service manual, section OB, for further details on change intervals.
General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.
© Copyright General Motors Corporation. All Rights Reserved.

Originally Posted by Mr. Ralph Holmquist of Eaton

"The maintenance schedule for the rear axle was developed by American Axle &
Manufacturing and GM truck based on multiple tests. The Eaton locker does
not require additional maintenance nor does it add heat to the lube. The
lube will darken due to the carbon wear on the clutch surfaces, much the
same as a disc brake pad & rotor. This does not damage axle components such
as seals or bearings. However, a new axle can produce excessive
temperatures (plus 350 degrees F) due to the ring & pinion breaking in that
will break the lube additives down. Avoid high loads, trailer towing and
high speed extended driving during the initial break in of the vehicle.
After the break in period axle temps will level at a much lower figure.
Lube changes are a good idea because the additives are replenished and
contaminates such as casting sand are eliminated. The axle is filled at the
factory with a synthetic 75w90 GL5 rating made by Texaco under part # 2276.
The GM service # is 12378261. This is the only lube we have done extensive
testing with to insure locker compatibility. The only negative to using one
of these other lubes is an increased potential for clutch chatter. This
really doesn't hurt anything and can be corrected by changing the lube. I
noticed in the latest GM owners manual the term "or equivalent" when
referring to the lube specification. Look for a GL5 rating on the bottle to
make sure the ring & pinion, seals & bearings are protected. Limited slip
additive is not needed."

Originally Posted by Tx Firefighter (Post 6328250)

I was just boning up on the details for this phase of the project by reading the "14 bolt bible".

http://www.pirate4x4.com/tech/billavista/14b_bible/

One thing that caught my eye....axle assembly with brake drums weighs 550 pounds.

Damn. I knew it was heavy, but that's a man killer right there.

Originally Posted by flashed (Post 6329221)

Those parts turned out great and I would never of thought of recycling a wheel chair like that ,pretty cool idea .

Originally Posted by Trekster (Post 6329985)

Great work. I really like the zinc plating idea. I have been using the "remove rust with vinegar and spray with aluminum paint" trick. It works...OK. I will try and find a plating shop closer to me.

Again, great work.