My truck came with a G80 3.73 equipped 8.0 rearend. While it has done alright with my big tires and multitude of modifications, I have always wanted more strength and reliability than the G80 8.0 offered. I have the sensors out on the end of the axle tubes requiring an 06 or newer rear and never found a 8.6 for a decent price. I got it in my head to swap to a lower gear set as well with the 35s going on as a permanent fixture soon. The front diff was the real sticky part in the gear change, but I found a decent price on a unit from an SS offering 4.10 gearing and the guy happened to have a 4.10 SS rearend as well. Bought them both as a good package price. The SS rear has 4.10s and a G86 limited slip rear differential. While the gears were to my liking, the LS was not going to meet my needs. I found a new in box LockRight lunchbox locker and snapped it up, but to facilitate its use I needed an open carrier. I sourced a used open carrier from WFO Concepts and got them to press on some new Timken bearing before shipping it and a super shim kit to me.
So now I had all the parts to step up from the 8.0 3.73 G80 rear to a locked 9.5 4.10 rear. The SS rear is a semi-float 14 bolt often found in 3/4 ton truck and in all SS TB's. It boasts a 9.5 inch ring gear, 33 spline shafts of good diameter. The general consensus is that this is about the equivalent of a Dana 60. Much stronger than my setup was.
I thought of attempting the carrier swap myself, but decided that enlisting some help from experienced friends would be much better. Even though I really was only concerned with backlash and pattern, I am glad I did not go it alone, but would not hesitate to do it again. Had the rear came with an open locker, this would have been a couple hour drop in job, but since I had to swap carriers...no quite so easy.
How about pics....
The Donor...08 SS
Junk stripped off
Ready to get to swapping
The help and axle on the sawhorses- Started about 8 Friday night
The locker
The motivation
Sticker in locker box
Cover off- Actually really clean with no metal clunks
Dirty inside
Cleaned up inside
The LS carrier had no gussets for strength
The open carier did...
Work
Help
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