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Discussion Starter · #1 · (Edited)
Well I have been slowly and I mean slowly gathering parts. after realizing I Had to much money wrapped up in the 2500 it was not worth starting over so I figured build what you got. So here is whats been done over the summer.
All new fuel lines
New Red head steerign box
Complete front end via Moog
PPE HD Tie rods
Powerstop brakes al 4 corners
New weater pump
new glow plugs.
Now parts I have just purchaced awaiting to start. a set of 04 1 ton springs and bump stops form an 05 Tennesse Duramax, Complete Dually rear form an 03 with stock wheels ( no tires) front 1 ton hub spacers, still trying to figure out how to run my 285x75x16 tires ( becuase I have them ). Right now it looks like steel adapter and have too bore out 2 wheels to a ford ID of 4.88 or come up with more cash and buy aftermarket wheels that have Acorn nuts but still need spacers. Oh and I also placed my order for the Dually rear fenders for a Short bed pics below
YA the short bed issue I forgot to mention that. Pics as I get progress. Right now is revamping the rear axle. ( which has yukon shafts already in it). I just as of this weekend got it off the ground and up on stands to work on it comfortably.

ALL PARTS USED ARE LISTED IN POST #4 under the RED

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So are the differential internals Yukon as well (if you know)?
 

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Discussion Starter · #3 · (Edited)
So are the differential internals Yukon as well (if you know)?
Unfortunately no, it has the stock Gov Bomb. I was hoping that since the axles were replaced the reason was the rear end let loose and all was upgraded. But sorry to say no, I would like to put the dodge carrier in it but right now money is tight and I have to grab the low-hanging fruit. Also, it is a bitch trying to find part numbers for the DRW. I bought a couple of things to find they were for the SRW 3500 and not a DRW.
 

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Discussion Starter · #4 · (Edited)
Adding some content
Break surface to mounting 5.5”

Rotor to Rotor 63”

WMC to WMC 74”and change

Spring pad is only ¾” off axle on DRW 3500

Spring pad is only 1.5” off axle on SRW 2500

FROM DIESEL HUB

AAM 11.50 REAR DIFFERENTIAL

AAM 11.50 INCH AXLE/DIFFERENTIAL SPECS & INFORMATION


The AAM 11.50 inch is a full floating, heavy duty differential found in GM, Dodge, and Ram Trucks applications. Beginning in 2001, GM replaced its popular 14 bolt rear differential in 3/4 and 1 ton pickups with the AAM 11.50. The AAM's 11.5 inch ring gear is significantly larger than the 14 bolts 10.5 inch ring gear, and the gross axle weight rating of the AAM model is approximately 1,500 lbs greater. Dodge began using the AAM 11.50 in its Ram 2500 and 3500 models for the 2003 model year, which coincided with a major redesign of these models. The axle was used in both single and dual rear wheel ("duallie") applications.

RELATED:
AAM 9.25 IFS Differential for GMC/Chevrolet Trucks

GM 10.50 in 14 Bolt Rear Differential Specs

Dana 80 Rear Differential Service Procedures & Information

Dana 60 Front Differential Service Procedures & Information

Although similar internally, GM and Dodge/Ram versions of the axle assembly are not interchangeable due to differences in the axle tubes, hubs, and brake/suspension mounting bracketry, although both use 30 spline axle shafts. Early GM units (until the 2014 model year) relied on a paper differential cover gasket while later GM and all Dodge/Ram assemblies employ a reusable rubber gasket, prompting simplified maintenance. ACDelco 23445892 is cross compatible across both variations for all model years and replaces the early GM paper gaskets. The 2014+ AAM axle for Ram applications features provisions for the Ram 2500/3500 rear coil spring suspension system and thus is not cross compatible with any of the leaf spring applications.

AAM 11.50 DIFFERENTIAL SPECS

Manufacturer:
American Axle & Manufacturing
Years Produced:
2001 - 2019
Applications:
2001 - 2019 Chevrolet Silverado/GMC Sierra 2500HD, 3500HD
2003 - 2009 Dodge Ram 2500, 3500
2010 - 2019 Ram Trucks Ram 2500, 3500
Housing Material:
Cast iron
Differential Type:
Full floating rear differential
Ring Gear Diameter:
11.50 in
Axle Spline Count:
30 spline
GAWR:
~10,000 lbs (GM rates @ max 9,375 lbs, Ram rates @ max 9,750 lbs)
Ratios:
GM Applications​
3.73 : 1, 4.10 : 1, 4.63 : 1
Dodge/Ram Applications:​
3.42 : 1, 3.73 : 1, 4.10 : 1
Carrier Break(s):
None
Drain Plug Torque:
34 - 54 ft-lbs (25 - 40 N-m)
Fill Plug Torque:
34 - 54 ft-lbs (25 - 40 N-m)
Differential Cover Bolt Torque:
43 - 62 ft-lbs (32 - 46 N-m)
Differential Cover Gasket[1]:
ACDelco 23445892
Lube Oil Spec[2]:
GM Applications​
SAE 75W-90 full synthetic gear oil
Dodge/Ram Applications:​
SAE 75W-90 full synthetic
75W-140 full synthetic gear oil
Lube Oil Capacity[3]:
3.8 - 4.2 U.S. quarts
Identification:
14 bolts securing differential housing to cover


List of parts used for the rebuild

Stock Replacement rear diff cover Dorman 697-712 Rear Differential Cover for Select Chevrolet / GMC Models
Rear Diff gasket LubeLocker AAM 11.5” Differential Cover Gasket
Rear Dust shields Dorman 924-214 Fits 2500 and 3500 DRW
Parking brake lever Dorman 924-743 Parking Brake Lever Kit for Select Models
Spindle nut square stock Dorman 615-140 Axle/Spindle Nut Retainer
Parking brake Shoes Power Stop B771
Axle seals GM Genuine Parts 291-319 Rear Axle Shaft Seal
Rear Brakes DRW Power Stop 1-Click Z36 Extreme Truck and Tow Brake Kit K5337-36
ACDelco RW20-07 GM Original Equipment Rear Outer Wheel Bearing
ACDelco RW20-08 GM Original Equipment Rear Inner Wheel Bearing
Raybestos H7330 Professional Grade Parking Brake Hardware Kit
1" Block kit For Chevy GMC Full Size SUV / Van 1" Inch Rear Lift Level HD Steel Block PRO KIT | eBay
14" Ubolt kit 5/8" x 2.6 x 14 Rough Country 5/8"x2-5/8"x14-1/2" Square U-Bolt Kit-Set of Four; 7666 | eBay
Rear AXLE SS brake lines

TRA0004SSTRA0004SS- 01-07 GM 3500 Dually Rear Axle Brake Line Set; Stainless
 

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Discussion Starter · #5 · (Edited)
Also I got word my Short bed rear Dually bed sides should be shipiing Thursday or Friday
 

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Discussion Starter · #6 ·
Does anyone have a 2500 Axle laying around that could verify the measurement from the top of the Spring pad to the top of the axle is 1.75" ?
 

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Discussion Starter · #7 ·
Got conformation the short bed dually rear bed sides have shipped!
 

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Discussion Starter · #8 ·
Spent yesterday pulling the axle apart, to start cleaning it up and replace breaks and rebuild the parking brake. Dr side pc of cake PAss side not so much this is the side someone replaced the axle shaft with the new Yukon. I found the crammed in a pc of square stock instead of the correct key and it is stuck in the slot pretty tite. And they did some other damage some of which may have been from the axle breaking.
 

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Discussion Starter · #9 · (Edited)
Well slowly pecked at it with a drill until I could get a tap started and was able to get the chunk of stuck key out. The spindle only has issues in one spot and it's before the area the nut sets when torqued so some cleanup is involved but it's apart. Some people should not be allowed to live!

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Discussion Starter · #10 · (Edited)
Well more work and parts have arrived.. Drained the diff
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Pulled the cover for an inspection to see why the shaft was replaced. Found stock locker and only the Pass side axle was replaced with the Yukon. ( much beefier than stcok )
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Measured the pad height to find out which size block you need. ( DRW pads are shorter the SRW pads )DRW .75 off the axle SRW pads are 1.5 of the axle. if you want level you will need a .75" block. I ended up machining a 1" x 2.6" x 6" block complete with the pin boss instead of tig welding something in like what companies are selling.

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Ripped the ends off for clean up and to see ig Parking brakes exist YA NO

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Started wire wheeling the axle housing. and have all the littel tabs and caliper brakets sitting in a bucket of Viniger.
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Parts started showing up. New seals, parking brake, parking brake hardware, new bearing snad races, New Ubolts, 1" lift blocks, new Spindle Keys, New diff cover, and lub locker seal, Power stop drilled slotted rotors and pads. Stainless Axle brake lines from inline tube. I will end up reusing my SS braided from the rear of the SRW caliprs and center drop ( maybe) if I find some xtra cash I may just get new.

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Discussion Starter · #11 · (Edited)
New diff cover and seal
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A little Muiratic acid for teh cleanup

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this is just MHO , but unless this is a race truck , get the drilled rotors and pads returned and get 100% factory GM pads and a real good quality rotor or GM OEM rotor, drilled and slotted rotors and trick pads are a huge waste , will stop real well for a while , will wear out quickly and be useless in short order. You can do some research on this if you want. Rear brakes on a dually will wear out way before fronts and slotted and drilled rotors even faster, I only have 1 + million miles on dually's and have been there done that believe me.
 
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^+1

But get ac Delco OEM and not the lesser line from Delco


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Slotted rotors are fine, but I have seen to many driller rotors crack, no matter what brand. I whill get OEM originals pads and rotors next to around. I also drag race and have no problems stopping

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Discussion Starter · #15 ·
I have owned GM trucks all my life and have never liked the way they stop. I am doing what I have already done to the current rig and it will rip you out of your seat when I stab the brakes. I have heard every debate out there and value you have an opinion. But I dont like them adn what I am doing has already proven to work onthe current truck so why change.
 

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I am used to a lot of hard miles and heavy loads, sounds like you know what your needs are and it looks like your not cutting corners on the project, just watch them , had 3 drilled rotors crack badly on the front. I am looking froward to watching your build !!
 

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Discussion Starter · #17 ·
I am used to a lot of hard miles and heavy loads, sounds like you know what your needs are and it looks like your not cutting corners on the project, just watch them , had 3 drilled rotors crack badly on the front. I am looking froward to watching your build !!
Interesting on the cracks, we used to see that with our Race cars in the day. The best rotors I have ever run were the EBC Dimppled and slotted but they are expensive. I then ran the POWERSTOP on my Tahoe and fell in love with the breaking. And then of course the notoriuos GM BS breaks smooshy pedal system on the 2500s ( classic) I have done everything and never could achieve a pedal worth a shit or it was one day great and an hour later shit. I did everything thing from power bleed gravity bleed, change out PS pump for better pressure, New lines, added a cooler. Nothing ever seemed to help unitl I put these breaks on. Was it perfect No but I could stop my 18000#. Toy hauler. Then I did the 2011 Hydro boost upgrade and WOW. Is it the be all end all, no is there better ? probably I know there is a lot worse. As for the Swap at all its only because of Hauling the new Toy hauler for saftey and some pc of mind. Problem was I thought this was my forever truck and after dumping $10,000 into it in Upgrades and Maint I realized I needed a Daully. ( and I was not starting over ) So here we are Not starting Over just improviong. Besisdes whoe doesnt love the look of a Unicorn with Duals LOL
 

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Discussion Starter · #18 ·
Rear brakes on a dually will wear out way before fronts and slotted and drilled rotors even faster, I only have 1 + million miles on dually's and have been there done that believe me.
Why do you think that is, the proportioning I would assume is the same? And if it is mechanically different from a 2500 to 3500 mine would still be Byass to the 2500 as I am only swapping the rear end.
 

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I have been told its cause I tow so many miles the weight is proportioned on a dually to the rear depending on the pin weight, I have had 5 and everyone has at least 2 to 1 on rear vs fronts. I do put 95% of my miles towing
 
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Discussion Starter · #20 ·
I have been told its cause I tow so many miles the weight is proportioned on a dually to the rear depending on the pin weight, I have had 5 and everyone has at least 2 to 1 on rear vs fronts. I do put 95% of my miles towing
Good to know, I will have to see how it works out considering my truck is starting out a 2500 SRW.
 
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