Rebuilding a 2004 Suburban rear differential- how hard

[GON]

A co-worked from many years ago now lives in Wisconsin and hit some hard times. He called me for a recommendation.

The co-worker owns a 2004 Chevy Suburban. He has been told his rear-end/ differential is shot. The mechanic he brought the Suburban to stated they won't touch it.

Any thoughts on the challenges and/ or cost to rebuild a rear differential in a 2004 Chevy Suburban? I assume the vehicle is a rust bucket.

 

[dfarr67]

option:

1/ buy a good used diff.
2/ just pay a pro to do it.

Been down this road too many times- needs to be set up right the first time. Been a few years and I was always upgrading too trutracs- but never cost less than $1500. And when I had a friend/mechanic do it- it cost me another set of bearings and a guy to set it straight.

 

[Ursatdx]

Perhaps a used diff might be better.

 

[Kestas]

I understand diffs aren't easy to dial in properly. There are pros that know how to do it. I would farm this out to a professional.

Perhaps a used diff would be a simple plug and play.

 

[StumblingElk]

I understand diffs aren't easy to dial in properly. There are pros that know how to do it. I would farm this out to a professional.

Perhaps a used diff would be a simple plug and play.

I would absolutely just find a used or rebuilt diff. Way easier and they made a bazillion of them over the years. Finding one shouldn't prove too difficult

 

[crashz]

I've rebuilt a 14 bolt rear, but they are pretty easy to do and get adjusted. Dana axles are not. The 10 bolt in your friends is sort of in the middle. Either way, the cost of bearing, seals and possibly gears may make it more affordable to find a good used axle instead.

 

[QwikKota]

Junky yard dog.

 

[GON]

Great input Gents, thanks kindly.

Based on the replies, seems a used differential is the least risk. Seems a costly repair.

This man is in his 60s and having financial difficulties. Bad time to have this happen. I am going to start looking at some rust free vehicles as a alternative option for him.

 

[GON]

Junky yard dog.

My concern is the Suburban has spent 22 years in Wisconsin. I suspect the truck is a rust a rama, and any service will uncover more critical service needs, like brake pipes, etc.

 

[D60]

My concern is the Suburban has spent 22 years in Wisconsin. I suspect the truck is a rust a rama, and any service will uncover more critical service needs, like brake pipes, etc.

GM spring plates are world's dumbest design under the axle. They hold dirt which holds moisture which sits and eats at the tubes. Even here in SW CO.

Expect the tubes to be seriously eroded if the plates are disturbed. Also another strong argument for a u-bolt flip, placing the plates on top of the springs as God intended.

This is a 2nd Gen Ram but Dodge just copied 90% GM when they built trucks

This is the general spring plate design on the bottom of the axle tube

Erosion in CO where almost nothing rests

Testing a u-bolt flip. I filled the tube with weld and sanded round-ish to eliminate the gap(s) you see then installed u-bolts and torqued. I build my own upper spring plates.

 

[D60]

Also if has or can obtain a dial inch lb TW, pinion yoke holder, small hydraulic press and clamshell bearing puller, it's not rocket science. Plenty of vids to walk you through it.

That said, doing this without a lift or without the axle on the bench (custom fixture, really) is for 20 year olds.

I'll never do a gear install if I can't be standing on my feet -- unless I'm absolutely stranded.