8.25 front parts swapping questions.

nyceguy01 · Nov 19, 2019

Im swapping out my rear axle this weekend in my 97 Tahoe.
Im all good on the rear but the Front diff from my parts truck is a 1991 with the Thermal Actuator.
My Tahoe is a 97 with Electric and obviously, Id like to stick with the Electric one.

I know they make a conversion with a spacer but what parts are actually different ?

Is it the tube itself that the actuator screws into or the internal plunger that moves the shift fork ?

Im hoping I can just take the parts from the 97 Diff and use them on the 91 Diff before I swap it in.

Anyone know what parts are different and if they can be just swapped ?

Im swapping in a rear 14 bolt SF with 4.10's so I need the 91 Front diff with the same ratios.

evilunclegrimace · Nov 21, 2019

Just use the electronic actuator AND the metal puck and you will be fine. the right side tubes are basically the same, the early tubes are aluminum and the later tubes are Iron.

nyceguy01 · Nov 21, 2019

Will the late tube swap on to the early center ?
Is the tube what is different making the puck necessary ?

nyceguy01 · Nov 21, 2019

Also, anyone have the dimensions of the spacer ?
If I have to go that route I'd rather not spend $50 on a wiring harness I dont need just to get the spacer...

evilunclegrimace · Nov 21, 2019

nyceguy01 said:
Will the late tube swap on to the early center ?
Is the tube what is different making the puck necessary ?

As far as I know they will swap but there is no need to swap the tube to change from the ***** to the electronic actuator
NO, the puck is required because the electronic actuator does not throw as far as the thermal *****. The tube dimensions do not change only the material that they are made of

nyceguy01 · Nov 21, 2019

If the tube is the same what parts are different ?

Is there just a spacer in the newer axle and I’ve just never noticed ? It’s not like it’s a part that’s out often.

I tried to find a diagram but between the years the diagrams are the same so I can’t just compare part #’s.

If the shift shaft or something else is different I would think I could just swap it out on the bench before I toss a diff back in.

evilunclegrimace · Nov 22, 2019

All that you have to concern your self with is the puck and the new electronic actuator. Pull out the old thermal actuator and install the puck in the hole and screw the electronic actuator. Do not worry about any thing else. You are making this harder than it needs to be.

They only other thing you will have to do if you truck has not been updated to the new style actuator is to install the new wiring harness update for the electronic actuator

John Carlsen · Dec 30, 2019

So did the newer diffs with the electric actuator have the little puck or was the mounting different.
I just swapped a thermal diff into an electric style and diddn't notice any spacer in the one we took out ( electric acutated)
With all the info out there I am wondering if we need the spacer in a thermal style actuated diff that was swapped into the electric actuator truck. we just removed the thermal activator that came with the diff and screwed the electric motor style actuator in.

Has anyone had the two together on the bench extended?

studigggs · Dec 31, 2019

On my '90 K1500 I bought a reman IFS. Not sure what year they sent me (I sent them all the correct info) but the shift fork on the one they sent wouldn't press on my front axle indicator switch so the 4WD light was always on (floor shift). They sent me back my original IFS and I swapped the shift forks to make it work. Just something to keep in mind.

8.25 front parts swapping questions.

nyceguy01

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evilunclegrimace

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nyceguy01

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nyceguy01

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evilunclegrimace

Does not always play well with others

nyceguy01

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evilunclegrimace

Does not always play well with others

John Carlsen

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studigggs

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