Rebuild front differential

[Kmcmjmtm]

Got a loud noise from front end. Pretty sure it's the front diff, so I'm gonna pull it and crack it open.
is there a thread on this somewhere or any info anywhere?
Any suggestions on rebuilding it (upgrading, where to get the rebuild kit)I'm not sure I can tackle that but not finding a lot of options without spending $3k for an assy.

any help is appreciated.

 

[SuperBuickGuy]

cast iron or aluminum case?

if it's cast iron, you can upgrade with an electronic locker... if it's aluminum, get the cast iron case.

 

[4speedfunk]

Dumpster the broken one.
Buy a used one from a wreck.
Bolt it in.
Fill with fluid.
Repeat.

 

[Scarsman]

The H2 only had an aluminum front diff. There is no cast iron option.

There isn't really anything to upgrade, unless you want to install a locker, do cryo treated gears, or change your gearing.

If you are not experienced with diffs and setting up gears then you may be over you head. However, you can pull the whole diff out and take it to a shop and save money on labor over them pulling it and installing it.

Also, if you did not already know, the H2 front diff does not have a cover. It is two halves that bolt together. So to inspect the inside you have to pull the whole diff out of the truck and split it open.

 

[Zach]

What year is the 2? If it is 03-04, they had a weaker case. 05 up it was redesigned and stronger. I wouldn't waste the time rebuilding an earlier one. If you do decide to add an elocker, I would recommend using it on a needed only basis. If you have any wheel spin, more than likely you will bust a halfshaft. More than likely, it will be the right side. Know from experience and another member here. It has gotten me out of a few tough spots. But, I rarely ever use it.

 

[Kmcmjmtm]

Thanks guys,
it's not my DD so I'm trying to get all my ducks in a row before pulling it.

is there a thread or step by step instructions for pulling the front diff?

do/can I leave the half shafts on the truck or do I pull the whole thing apart piece by piece

its an 05 and I found a buddy who says he can handle the rebuild

 

[Kmcmjmtm]

No help on the tear down huh?

guess I'll dig in

 

[Kmcmjmtm]

OK,
That was pretty straightforward for future reference or for beginners like me.

1) pull four bolts holding cross member brace in place.
2) pull four bolts holding u-joint cap in place on front of front driveshaft
3) pull bolt holding diff to cross member brace ( you may or may not have to do this, my bushing looked "funky" so I did it anyway) if you don't pull this it may be easier to balance the assy as you pull it out.
4) pull six bolts each from axle flanges
5) pull bolt out of passenger side "stub shaft" but leave the bolt in place til ready to drop diff assy
6) remove vent line hose
7) remove bolt on driver side holding assy to frame ( this one is vertical)
8) I forgot to mention you will need a jack to support the diff somewhere in this process...lol
9) lower jack while working towards pass side to remove. No big deal

now for the rebuild, any ideas where to get a master set with ring, pinion, the whole enchilada???

 

[cdarveaux]

The dealer? I know they should have them if not be able to order them? That's what I'd do but if my front diff busted I'd pull it out toss it and get another just a lot easier but I get what you're trying to do