4.11's and G80 posi in 2005 AWD

IF YOU HAVE QUESTIONS ON THE REAR DRIVE SHAFT OR AXLE, IT GOES HERE.

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LiftedAWDAstro
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4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

Ever since I put 4.11's in the SPB back in 2003-4, every van I bought and kept for a while has had 4.10's. This 05 is no different. Going with 4.11's with a G80 posi in the rear and 4.10's up front. The reason for the 4.11/4.10 difference is simple. The rears are 9/37 meaning 9 teeth on the pinion and 37 teeth on the ring where the front is 10/41. Basically they are interchangeable.

I got the gears, posi and install kits from snapple as he had bought them for his van. I was originally going to install these into his van and am glad the issues I am having are on my van and not his! The rear gears and posi are used GM units and are in great shape.

The first attempt at the install met with lots of swearing, bumped head, banged up knuckles and knees because I tried it under the van. I failed and could not get a decent pattern. Every time I installed the pinion the measurements changed. Adding and subtracting shims made no real difference. After 2 days the rear was buttoned up and I was hoping it would be ok...NOT! Never even made it out of the driveway it was so noisy.

First attempt:

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Crawling under here for the pinion work sucked!

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Original gears looked great and the oil was black but very little metal particles on the magnet.

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Used GM 4.11 ring and G80 posi ready to meet!

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4.11 pinion installed.

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It was after this I stopped taking pics due to frustration! After 2 days of swearing I walked away for 5 days. After talking to my buddy Darrel who has done many gear swaps in Jeeps, we decided the problem might be the china bearings in the install kit. I decided to order a new Yukon master install kit complete with Timken bearings. In the meantime, I pulled the axle out to work on the bench.

The problem wasn't the bearings...it was ME! ](*,) ](*,) ](*,) When I pounded the larger pinion race into the housing, I never got it seated all the way. It went in very hard so I thought it was in all the way. That is why my measurements kept changing.

This is where that race goes in:

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Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
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Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

More to come later!
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy
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Smiliesafari
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Re: 4.11's and G80 posi in 2005 AWD

Post by Smiliesafari »

Much to my disappointment I recently learned that Timken bearings are now made in China. When I fabricated the 12 bolt rearend for my van it was recommended (by Dutchman Motorsports, they made my axles) that I use the large Ford 1/2 ton pickup bearings on the axles. One would think that truck axle bearings would work fine. The bearings that came with the axles were Timken. Printed on the box "Made in China". Since the rearend has been in use I have lost 4 bearings. I have since modified the axles to accept roller bearings. Also made by Timken. We'll see how these work. I understand you're frustration, Dean. I'm really tired of working on this rearend.
1996 Safari SLX Hotair balloon transport vehicle

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LiftedAWDAstro
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Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

Maybe I'll just have to re-use the old USA made bearings that still look great!

Pulled the axle out and placed it on jack stands on the bench.

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Right now it is all apart awaiting the Yukon install kit.

Debating on replacing the backing plates and parking brake shoes while it's apart...

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Problem is the backing plates will just rust out again in a few years and the shoes are over $32 each at Rock Auto! The backing plates are about $23 for the pair. Hard to put another nearly $100 into something that doesn't get used. Most likely not gonna replace them.
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy
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Re: 4.11's and G80 posi in 2005 AWD

Post by MountainManJoe »

Good pix. Thanks. Keep 'em coming.

Topic author
LiftedAWDAstro
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Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

It'll be a little while...the install kit just shipped today and we'll be camping the next 2 weekends plus working. It'll be done by the 22nd of June for sure!
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

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Re: 4.11's and G80 posi in 2005 AWD

Post by photo_van »

looking forward to frontend pics too!!
1998 AWD/4WD
4" lift, 31x10.50's, NP 242j/c hybrid, 4.10 gears, S10 front disconnect, rack & pinion steering, trans cooler, rock sliders, ARB fridge, house battery and 100w solar, swing out rear rack with foldout camp table, bed and passenger swivel chair
dirt bag camping rig
1981 Toyota 4x4 pu
1974 John Deere 710
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snapple
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Re: 4.11's and G80 posi in 2005 AWD

Post by snapple »

LiftedAWDAstro wrote: I got the gears, posi and install kits from snapple as he had bought them for his van. I was originally going to install these into his van and am glad the issues I am having are on my van and not his! The rear gears and posi are used GM units and are in great shape.
Sorry to hear about the hassle this has been! But must agree,glad this wasn't my van! I never would have heard the end of it from Amy! The van I was originally planning on installing the gears in is going to be ravaged for alot of parts this weekend. Im taking out the updated torsion bars and all the " new" front end parts I put in before parking it and swapping them into the '95 this weekend. Hope both our jobs go smoothly here on out! :cheers:
'94 Astro AWD EXT LT - Over 211,000 ,parts van now!
DHC Rock rails
Overland Vans 4" lift kit and bumper w/grille guard
Fiamma awning

'95 Astro AWD EXT CS - Just over 99,000 miles
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Re: 4.11's and G80 posi in 2005 AWD

Post by arlon »

I'd love to have a set of 4.10's in my van! Hassle or not..
2004 AWD Astro 2" lift, overnight-able
2003 Dodge/Cummins Quad cab
2006 Nissan X-terra MT
1985 LTD LX 5.0 HO
Plus wife's and kid's cars to take care of...

Topic author
LiftedAWDAstro
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Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

snapple wrote:Sorry to hear about the hassle this has been! But must agree,glad this wasn't my van!
I am SO glad this is on my van! I would have been banging my head bad! You would have had to take my van home...just tell her you traded! :muhaha:

Good luck with all the weekend projects. I know from now on out the rest of the swap will be a piece of cake. We are going camping so no working for me! :drinkers:
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

Look for an update tonight! Gonna be working on it today. :supz:
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

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Re: 4.11's and G80 posi in 2005 AWD

Post by astrozam »

Cool, hope you enjoyed the campin trip

Topic author
LiftedAWDAstro
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Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

Camping was awesome as always!

Got the rear gears/posi installed and in the van and test driven. I just need to reprogram with the Jet module and see how she responds.

I installed all new Timken races and bearing with a 0.035" shim under the pinion. This was the shim that was used with the 3.42's. I then went to setting the backlash. First attempt put me at 0.012", second attempt put me at 0.010":

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I then made more adjustments to the carrier shims and ended up with 0.008" backlash.

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Pattern before final install:

Image

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Image

Image
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Re: 4.11's and G80 posi in 2005 AWD

Post by LiftedAWDAstro »

I then put a new pinion seal in and added the crush sleeve to the pinion.

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I then tightened the pinion nut to 18 inch-pounds which is just over spec but to make it 15 or less would require taking it all apart to replace the crush sleeve. Yukon does make a crush sleeve replacement shim pack but it was another $20 so I decided to not use it.

Final gear pattern:

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Here you can see the C-clips that hold the axles in place:

Image

The rest was replacing the axle seals, putting the cover on with RTV, filling with 80-90 gear oil, and installing into the van.
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

photo_van
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Re: 4.11's and G80 posi in 2005 AWD

Post by photo_van »

=D> Nice job! Quiet? I've got the front end all apart in the shed waiting for parts!
1998 AWD/4WD
4" lift, 31x10.50's, NP 242j/c hybrid, 4.10 gears, S10 front disconnect, rack & pinion steering, trans cooler, rock sliders, ARB fridge, house battery and 100w solar, swing out rear rack with foldout camp table, bed and passenger swivel chair
dirt bag camping rig
1981 Toyota 4x4 pu
1974 John Deere 710
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