Accidentally purchased a denali front differential to match gearing in my rear end.

[Kungfubenny]

I purchased a Denali transfer case with 3.73 gears but did not realize it doesnt have plug in for the selector switch. Is it possible to swap out some parts from my stock front diff to the denalis to make it work??

My stock rear end blew and i swapped it out last year with a junk yard part. My truck was gu6 front and back with 3.42 gears. It now has 3.73 open diff in the rear. After sourcing a front diff on offer up (cheaping out) with 3.73 i failed to realize it wasn't compatible in terms of plug and play.

Any suggestion will help? Can i rebuild it or am i better off re-selling it and getting the front diff i actually need GT4 rpo.

 

[Doubeleive]

I purchased a Denali transfer case with 3.73 gears but did not realize it doesnt have plug in for the selector switch. Is it possible to swap out some parts from my stock front diff to the denalis to make it work??

My stock rear end blew and i swapped it out last year with a junk yard part. My truck was gu6 front and back with 3.42 gears. It now has 3.73 open diff in the rear. After sourcing a front diff on offer up (cheaping out) with 3.73 i failed to realize it wasn't compatible in terms of plug and play.

Any suggestion will help? Can i rebuild it or am i better off re-selling it and getting the front diff i actually need GT4 rpo.

I'm not 100% sure but you should be able to just swap your actuator over to the AWD diff. If there is a place for it in the shell/casing

 

[swathdiver]

Pretty sure that's the way to do it. @Matthew Jeschke

 

[Kungfubenny]

I'm not 100% sure but you should be able to just swap your actuator over to the AWD diff. If there is a place for it in the shell/casing

Thanks for responding!

The axle tube housing is the only exterior difference that i can see.

I guess my next question would be if i could swap the tube housing/actuator on to the awd diff and if so would it still function the same way as stock with 2hi, 4hi and 4 low? Or will i need to modify the internals of the awd diff?

The photos below are of a 4x4 front diff and the awd diff

 

[Kungfubenny]

Pretty sure that's the way to do it. @Matthew Jeschke

If i swap the axel tube housing the actuator will it be straight forward swap or will i also need to tamper with the gears at all?

 

[Doubeleive]

Thanks for responding!

The axle tube housing is the only exterior difference that i can see.

I guess my next question would be if i could swap the tube housing/actuator on to the awd diff and if so would it still function the same way as stock with 2hi, 4hi and 4 low? Or will i need to modify the internals of the awd diff?

The photos below are of a 4x4 front diff and the awd diff

Pretty sure you can just swap it on there, the 4wd hi/lo drive part is handled by the transfer case, no worries on that portion

 

[rdezs]

Yeah, just swap the axle tube.

 

[Matthew Jeschke]

I've fiddled with my 4WD... Rebuild the tx case, front diff, etc. However, I've not swapped parts from other vehicles. Not 100% sure on fitment.

That said, probably the only thing would be that actuator on the axle tube. It may need swapped if the connector doesn't fit...

The AWD TX case is an NP246. Internals are pretty much same from what I understand across the model years... However, the encoder motor is different. The split year change (2003?) has a newer style encoder motor and probably a newer style 4WD controller.

Note: You'll also need the 4WD controller as well as button selector.

Let's start with this...

Year make and model of your vehicle. Did it come with AWD? Or was 4WD only. (the AWD has a special controller)

Year make and model of donor vehicles your parts came from.

 

[Kungfubenny]

I've fiddled with my 4WD... Rebuild the tx case, front diff, etc. However, I've not swapped parts from other vehicles. Not 100% sure on fitment.

That said, probably the only thing would be that actuator on the axle tube. It may need swapped if the connector doesn't fit...

The AWD TX case is an NP246. Internals are pretty much same from what I understand across the model years... However, the encoder motor is different. The split year change (2003?) has a newer style encoder motor and probably a newer style 4WD controller.

Note: You'll also need the 4WD controller as well as button selector.

Let's start with this...

Year make and model of your vehicle. Did it come with AWD? Or was 4WD only. (the AWD has a special controller)

Year make and model of donor vehicles your parts came from.

Thank you for responding!
My tahoe is an 05 with 4x4 push button 2hi/4hi/4lo. It came factory with 3.42 gearing(gu6 rpo). The front differential that i mistakenly purchased is from a Denali with awd with 3.73 gearing.

I originally purchased the diff with intent of a direct swap to match the rear end I'm currently running which is 3.73 that came from a part out once i grenaded my G80last year.

The new plan is to swap out the axel tube from my stock front differential to retain 2hi/4hi and 4low with the “new” front diff from the denali Essentially converting the awd unit to a selectable 4wd unit. Or would i be better off just sourcing the correct diff for straight forward swap out?

 

[Matthew Jeschke]

Its a bit of work to convert from or to a AWD from a standard locking transfer case. I am sure it can be done but I've not done it.

doesnt sound like that is what you are doing anyways... Yeah I'd just take gears and whatever you need from the purchased front Axle into your factory axle. I'd assume that would be easiest. Other than you may need to adjust gear lash etc

Sidenote, I have AWD txcase. Don't think I have ever used the AWD feature other than to see if it works

 

[donjetman]

This discussion should be in the 2000-2006 area.

 

[GMCChevy]

The other problem is whats inside that the actuator is controlling? With no provision for the actuator on the awd one it might not have that either. You are probably better off to either swap the gears only like what was mentioned or get the proper part.
If you swap gears make sure they're set up properly.

 

[swathdiver]

If i swap the axel tube housing the actuator will it be straight forward swap or will i also need to tamper with the gears at all?

Ok, I looked up a video that I've referenced in the past and you are good to go with just changing that tube.

Go to DemandAAM.com and look up the diagram for your front axle. In there, you'll see the differences between the 4x4 and AWD front differentials.

 

[Joseph Garcia]

I purchased a Denali transfer case with 3.73 gears but did not realize it doesnt have plug in for the selector switch. Is it possible to swap out some parts from my stock front diff to the denalis to make it work??

My stock rear end blew and i swapped it out last year with a junk yard part. My truck was gu6 front and back with 3.42 gears. It now has 3.73 open diff in the rear. After sourcing a front diff on offer up (cheaping out) with 3.73 i failed to realize it wasn't compatible in terms of plug and play.

Any suggestion will help? Can i rebuild it or am i better off re-selling it and getting the front diff i actually need GT4 rpo.

After reading all of the above comments, it would be much simpler if you found the correct front differential and be done with it in the form of a small project. IMO, there is no need to complicate this project to save a few dollars. Find the right front differential from a used parts house, and see if they will give you some credit for swapping the incorrect one that you have now.

 

[j91z28d1]

you're talking about just unbolting the end tube and swap them? if they are the same and it fits, I don't see what it would hurt to try.


that solenoid just locks the right wheel to the left wheel when in 4hi/4lo right? I mean if you don't use 4hi/lo often enough, maybe just pull the old actuator off the old one, plug it in and zip tie it out of the way? so it doesn't set a fault code for being unplugged.

 

[Fless]

This discussion should be in the 2000-2006 area.

So moved.

 

[rockola1971]

I've fiddled with my 4WD... Rebuild the tx case, front diff, etc. However, I've not swapped parts from other vehicles. Not 100% sure on fitment.

That said, probably the only thing would be that actuator on the axle tube. It may need swapped if the connector doesn't fit...

The AWD TX case is an NP246. Internals are pretty much same from what I understand across the model years... However, the encoder motor is different. The split year change (2003?) has a newer style encoder motor and probably a newer style 4WD controller.

Note: You'll also need the 4WD controller as well as button selector.

Let's start with this...

Year make and model of your vehicle. Did it come with AWD? Or was 4WD only. (the AWD has a special controller)

Year make and model of donor vehicles your parts came from.

AWD unit is a Borg Warner BW4481 (BW) Tcase. Not even close to the same as a NP246 (New Process/NVG-New Venture Gear). 2 totally different companies.

 

[rockola1971]

Thanks for responding!

The axle tube housing is the only exterior difference that i can see.

I guess my next question would be if i could swap the tube housing/actuator on to the awd diff and if so would it still function the same way as stock with 2hi, 4hi and 4 low? Or will i need to modify the internals of the awd diff?

The photos below are of a 4x4 front diff and the awd diff

The only difference between the AWD and 4WD front Diff (In the same generation) is the axle housing(Passenger side), electric shift motor and the shift fork assembly. You can swap your 4WD components over to the AWD unit. Its fairly straightforward.

 

[rockola1971]

you're talking about just unbolting the end tube and swap them? if they are the same and it fits, I don't see what it would hurt to try.


that solenoid just locks the right wheel to the left wheel when in 4hi/4lo right? I mean if you don't use 4hi/lo often enough, maybe just pull the old actuator off the old one, plug it in and zip tie it out of the way? so it doesn't set a fault code for being unplugged.

View attachment 453236

No. The shift solenoid locks the front driveshaft to the front diff.

 

[Kungfubenny]

After reading all of the above comments, it would be much simpler if you found the correct front differential and be done with it in the form of a small project. IMO, there is no need to complicate this project to save a few dollars. Find the right front differential from a used parts house, and see if they will give you some credit for swapping the incorrect one that you have now.

Thank you! I figured just getting the correct part would be the most straight approach to this situation. Id hate to mess them both up in the process of frankensteining the awd.