2002 2500hd front differential gear change

tclark2020 · March 6, 2007

I am replacing the gears in the front differential of my 2002 2500hd chevy truck and was wondering if anyone can tell me how to get the gears out of the housing. My truck was hit and broke the top mounting tab and so I have acquired another front differential that has a good case. Mine is 3.73 gears and the one I picked up is 4.10 so I need to do a gear swap. I have the case split, but am not sure how the gears come out to change them. Didn't want to break anything. Any other things I need to look for while doing the sway would be greatly appreciated. Thanks for the help.

Freyguy · March 6, 2007

I know there are some posts on fullsizechevy about doing gears in an IFS. I don't think we are allowed to link to other sites. A search over there should turn up some answers.

Valsport · March 6, 2007

i'd keep the 4.10's in the front and just bolt it up, and swap the rear to 4.10's

tclark2020 · March 6, 2007

Well, I got it all apart with minimal effort after a buddy stopped by and showed me where to hit. My only other question at this point is there is a collar on the pinion shaft that came off when the gear came out and I noticed that it has a small hump around it closer to one side than the other. Can anyone tell me if the hump goes closer to the gear or the bearing. Thanks in advance. Travis.

tclark2020 · March 7, 2007

I would have just kept the 4.10's, but I had to have the case and was trying to spend the least amount of money possible. I've already ran into a few more issues than I had planned. When I tore into the truck I hadn't seen the broken mounting tab on the differential case, and soon found out they don't give those away!! Thats how I ended up with a used case with 4.10 gears. Needless to say I am getting anxious to get it out of the frame shop so I can get it into my garage and get everything bolted back on and paint it. I have the garage ready and my wife is loving me for making her park outside again. (My side of the garage is full of a z-track mower, a lawn tractor, 790 John Deere with accessories, and a golf cart). I figure I may have to save some money to build a garage for my truck and toys!!

StoneyPgh · March 7, 2007

You will need a NEW crush collar when installing the pinion.

It might be a good idea to get a few extra pinion shims also.

tclark2020 · March 7, 2007

I picked up a new crush collar today, I will get some shims tomorrow. Still not sure what the collar around the pinion shaft is, (it fell off before I was able to see which way it went on).

tclark2020 · March 7, 2007

Well, now i feel stupid!!! After looking with my eyes open I have figured out that the collar I have been concerned with IS the crush sleeve. Oh well!! I was so concerned with this possibly being too complicated that I just wasn't paying attention. Looks easy now!!

Freyguy · March 7, 2007

I read on fullsizechevy that it is pretty hard to get the crush sleeve on correctly. One guy had a buddy who does gears at his shop do it, and he said that it takes multiple attemps sometimes. Said that you have to go by feel when putting it on. So you may need more crush sleeves.

I've never done them, so I can't comment. I just thought I'd pass this info along.

concours · March 11, 2007

Dude, the fact that you are asking these Q's means you are not qualified to set up differential gears. Gear mesh, backlask, contact pattern, carrier bearing preload, pinion bearing preload all have procedures that must be adhered to. There are tools and fixtures you need beyond your Craftsman stuff. A factory service manual would be a good start. The threaded side bearing adjusters on the IFS case are nearly always corroded in place, and will cause you serious heartburn. Don't be offended, just trying to save you frustration of a noisy, short lived diff.

stegs2 · September 16, 2010

I am replacing the gears in the front differential of my 2002 2500hd chevy truck and was wondering if anyone can tell me how to get the gears out of the housing. My truck was hit and broke the top mounting tab and so I have acquired another front differential that has a good case. Mine is 3.73 gears and the one I picked up is 4.10 so I need to do a gear swap. I have the case split, but am not sure how the gears come out to change them. Didn't want to break anything. Any other things I need to look for while doing the sway would be greatly appreciated. Thanks for the help.

Hello,

I saw your post regarding the extra 4.10 parts and wondered if you would like to sell your extra parts? I have a 4.10 front diff that needs help.

Bob