Tahoe Front Diff

Frankhenrylee · March 1, 2011

Hey fellas, whassup? I'm wondering who makes the best reman part for a 2002 Tahoe 4wd w/auto4wd. Also can you replace with the 9.25 3/4 ton unit? I found a 1/8"x1/4" chunk of metal stuck to the drain plug while changing fluid after noticing 4x4 was making a lot of noise. I just bought the truck and didn't notice any noise until the other day. It still makes a little noise now after fluid change, but its much better. I'd like to replace with heavier duty part or have rebuilt with better parts. 2wd seems to be fine. Appreciate the help!

jro909 · March 1, 2011

if you put a 3/4 front diff in you will need a 3/4 rear end also...otherwise it won't work...they will spin at different speeds

HawkScot · March 1, 2011

If you replace with 3/4 ton unit, it will spin at the same speed IF you get the same gears (3.73 or 4.10 or ??). that is not the problem, the problem is all the rest, such as the 3/4 ton will have 8 lug wheels, perhaps different mounting, etc.

Identify the metal chunk you found and repair as needed. Is it a piece from the 4WD actuator (I don't know if that is even possible)?

gmtech4 · March 2, 2011

+1 ,just get yours looked at ,could be nothing

Frankhenrylee · March 2, 2011

Thanks for the info so far. I had a 3/4 chevy before this truck and the 4wd never made so much as a peep. That truck had 250,000 on it. I just bought this one with 110,000 and the 4wd has started groaning and whining. I think it's this crappy push button Auto 4wd. I wish GM would have just left the floor shifter, a lot more solid if you ask me. I'm having a hard time finding a shop that knows there way around a differential, but I'll keep looking. Thanks for the help.

HawkScot · March 2, 2011

The push button 4WD is not different for the front differential vs the floor shifter. The floor shifter has a switch that powers the actuator on the front differential, I believe it is the same actuator. The transfer case on the other hand is a different one.

That being said, you could have a bad switch causing some grief (not sure how it would cause noise but perhaps)...

You find a new switch or have the old one rebuilt. modulemaster.com is one place to get them rebuilt, I have not had it done yet myself.

Are you sure the front differential is the source of the noise? could it be the transfer case?

Frankhenrylee · March 3, 2011

Pretty sure its coming from the front but its hard to tell exactly where. I took the piece of metal by the garage I think I'm going to use. They couldn't identify it specifically, said maybe part of the spider gear. They're saying $750-$1200 depending on what it looks like when they get it open. I'm taking it by my regular mechanic next week. I think I might get some different gears, but I'm not sure. I'm getting some bigger tires at some point but I don't know if 33's really need lower gears.

hqdoc314 · March 10, 2011

The piece of metal was most likely from the adjuster lock , common fail item in these front diffs, one of your carrier bearings is most likely trashed.