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Old 08-25-2019, 03:49 PM   #76
MalibuSSwagon
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Re: Hatzies 2005 2500HD

I purchased a local 2003 Silverado 2500HD crew cab a weeks ago. The not so rare New England crusty edition. I enjoyed your thread of fixes and additions to make it neater. Already installed a set of tricolor taillights I had lying around. I am wondering if you have pictures of the diff cover installed. I gotta change the oil, the stuff that came out when I did the rear brakes was a pretty nasty looking milkshake. I bought a Dorman cover with a fill plug but it appears to be for a 11.5 axle, which I don't think will fit. Not sure.
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Old 08-25-2019, 04:42 PM   #77
hatzie
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Re: Hatzies 2005 2500HD

The AAM 14 bolt axles came in three sizes 9.5" ring gear semi floating C-Clip axles, and 10.5" and 11.5" ring gear full floating bolt on axles.
The larger 11.5" cover will not fit the 10.5" axle even tho they are both full floating axles.

The 10.5" full floater is mostly the same animal as the old corporate GM full floating 14bolt in my 1976 K20 and 2000 GMC C2500 with a few differences like the 8mm metric cover bolts rather than the larger 3/8" bolts on the older axles.

I have a new Yukon YGA-32345 steel diff cover for the 10.5" axle in the garage that I bought for my 76 before I sold it but it doesn't have a fill plug welded in.

I'm not going to use the Yukon cover nor am I going to re-install the factory cover.
  1. The aluminum G2 cover isn't costing me fuel mileage.
  2. The aluminum G2 cover hasn't changed the diff temp appreciably either. I made a run to Providence to work on RIPTA equipment before and after. The G2 read the same temp as the steel cover on my IR thermometer so "running cooler" with this aluminum cover is IMHO complete BS. But it also doesn't seem to hurt anything.
  3. Both the steel covers would require work with the TIG to add fill plugs.

O2 sensors are 18mm x 1.5mm. You can get inexpensive 18mm magnetic fill plugs and weld in O2 sensor bungs.
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I don't have a picture of the G2 cover painted dark gray and installed. If I remember to take one I'll post it in this thread.
This is the ad copy picture.
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The G2 is drilled for 3/8" bolts and that's what it comes with. Once you buy the 8mm bolts from McMaster Carr, or wherever, the 8mm bolts will rattle around in the cover mounting holes like a BB in a boxcar.
The bolts you buy need to be longer than the original steel cover bolts without bottoming in the housing. I used 25mm long bolts.
I put copper sleeves as a shoulder around the 8mm bolts that I did indeed buy from McMaster Carr. You can see the chunks of soft 1/4" copper pipe cut shorter than the depth of the diff cover and split with the red razorblade knife in the picture.
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__________________
1959 M35A2 LDT465-1D SOLD
1967 Dodge W200 B383, NP420/NP201 SOLD
1969 Dodge Polara 500 B383, A833 SOLD
1972 Ford F250 FE390, NP435/NP205 SOLD
1976 Chevy K20, 6.5L, NV4500/NP208 SOLD
1986 M1008 CUCV SOLD
2000 GMC C2500, TD6.5L, NV4500
2005 Chevy Silverado LS 2500HD 6.0L 4L80E/NP263
2009 Impala SS LS4 V8


RTFM... GM Parts Books, GM Schematics, GM service manuals, and GM training materials...Please include at least the year and model in your threads. It'll be easier to answer your questions.
And please let us know if and how your repairs were successful.

Last edited by hatzie; 08-25-2019 at 04:50 PM.
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Old 08-26-2019, 10:40 AM   #78
MalibuSSwagon
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Re: Hatzies 2005 2500HD

I just bought the G2 cover on Amazon. $102 with free one day is not terrible. I've also seen the Gale Banks video on aftermarket diff covers and didn't want to spend $250 on a diff cover that might actually be detrimental. It'll be nice to have the drain plug too for more frequent rear diff oil changes. Usually i'm a junkyard dog and just slap things together with what i can scrounge cheap or free, but I got a good deal on this truck and want to keep it for 10 or more years.
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Old 08-26-2019, 10:53 AM   #79
hatzie
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Re: Hatzies 2005 2500HD

Quote:
Originally Posted by MalibuSSwagon View Post
I just bought the G2 cover on Amazon. $102 with free one day is not terrible. I've also seen the Gale Banks video on aftermarket diff covers and didn't want to spend $250 on a diff cover that might actually be detrimental. It'll be nice to have the drain plug too for more frequent rear diff oil changes. Usually i'm a junkyard dog and just slap things together with what i can scrounge cheap or free, but I got a good deal on this truck and want to keep it for 10 or more years.
The drain plug is window dressing and it's not truly at the bottom of the diff. The fill plug is the important thing in this cover.

I have yet to find an AAM axle with a really stuck drain plug. Not impossible but it's in the oil unlike the fill plug.

This cover is aluminium alloy and we're in salt central. They use a lot of calcium chloride on the dirt roads in Hillsboro county in the summer.
Paint all the exposed aluminum.
__________________
1959 M35A2 LDT465-1D SOLD
1967 Dodge W200 B383, NP420/NP201 SOLD
1969 Dodge Polara 500 B383, A833 SOLD
1972 Ford F250 FE390, NP435/NP205 SOLD
1976 Chevy K20, 6.5L, NV4500/NP208 SOLD
1986 M1008 CUCV SOLD
2000 GMC C2500, TD6.5L, NV4500
2005 Chevy Silverado LS 2500HD 6.0L 4L80E/NP263
2009 Impala SS LS4 V8


RTFM... GM Parts Books, GM Schematics, GM service manuals, and GM training materials...Please include at least the year and model in your threads. It'll be easier to answer your questions.
And please let us know if and how your repairs were successful.

Last edited by hatzie; 12-10-2019 at 11:20 AM.
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