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Differential and Gears Upgrade.
Submitted By: Mark42
Date Created: 12-04-2009
Description: The open differential and 3.08 gears are being replaced with a performance gear ratio of 3.73 and an Eaton Truetrac positive traction differential. This change runs about $550 in parts, and $400 in install. Estimates for the install of gears and carrier ranged from $200 to $800 for labor, so shop around. The best price came from a trans rebuilder/speed shop who does rear gears regularly and knows how to set the lash properly. Avoid the local shop, they don't do this often and mistakes are expensive.

The PCM (Power train Control Module - the cars computer) was sent out to PCMforless.com for reprogramming so that the speedometer will register correctly with the new gear ratio. They also modified fan speeds to match a lower temperature (180*) thermostat, shift firmness, and adjust fuel/air/timing to give about an additional 15hp boost to the car. Strongly recommend them.

It is important to note that if a PCM from a different car is re-programmed and installed in your car, the "CASE Learn" procedure needs to be done on the PCM after its re-programmed. (CRANKSHAFT VARIATION RELEARN aka CASE Learn). Basically it tells the PCM what the variation in the crankshaft position sensor is in your particular engine. It is a fine tune of the timing. Not needed if the PCM from your car is reprogrammed.


Update: 06/10/2010 (6 months later). No leaks, no bad noises, everything works perfect. The Summit brand gears do make a little noise. My passengers didn't even notice until I pointed it out, its that minor. After tracking fuel economy for a few thousand miles, there is no noticeable loss in fuel economy. The car averages 27 mpg, and can still get 30 mpg on a strictly highway trip. The car is much faster, passing is a breeze, and the firmer shifts are nice. Punch the throttle and the car leaves rubber for about 60 feet. Wheel hop was much worse after the gear change. Had the "hollow star" bushings in the rear control arms replaced with Moog solid rubber bushings. Problem solved. I recommend having the bushings upgraded when the rear is done.

Update 01/12/2011: Still no problems or leaks after about 20,000 miles. The Truetrac works great in the snow and rain. About 120 lbs of weight added to the trunk really helps in the snow, especially on steep hills. An aluminum drive shaft from a LS1 Trans Am was added and the gear noise has all but disappeared. I'm guessing that the aluminum does not transmit sound as well as the steel shaft so noise from the rear is reduced. Towed my boat a few times, the gears and Truetrac make the trip easy. Same with launching and retrieving the boat. It pays to buy quality parts and pay for qualified mechanics.

BTW, avoid Newgmparts.com. They messed up my order for a Reluctor Ring, and would not pay return shipping or give full refund even though they sent the wrong part. I even specified the part number in my order. Go figure. Very bad merchant.
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Eaton Truetrac
This is the Eaton Detroit Truetrac Limited Slip Differential (LSD). Unlike other LSD's that use clutches to lock the two axles together, the Eaton uses an all gear drive design to perform the same function. In addition to having no clutches to wear out, it operates totally smooth and silent. It will also last the life of the car without maintenance.

This is a 3 series carrier (for 3.42 and up gear ratios) taking 28 spline axles and a 7.5 in./7.625 inch ring gear.

To go along with the Eaton differential, a new set of 3.73:1 gears will replace the factory 3.08:1 gears. This will make towing my boats easier on the car, and when not towing the gears will give quicker acceleration. Impact to fuel economy should be minimal. Make sure you have the correct carrier series for the gear ratio being used.
3.73:1 Gears


PCM Update
A used PCM was sent for re-programming by PCMFORLESS.COM. They changed timing advance, shift points, corrected speedo for new gears, changed the radiator fan high/low on/off temps for 180* thermostat, and a few other performance changes.

The PCM I had reprogrammed came from another car, so a procedure called Case Learn was done by a GM dealer to reset the cranck shaft timing variation unique to each engine.

The new PCM and programming worked great. And most importantly, the speedometer is now correct with the 3.73 gears.

The gears and differential were installed and after the 500 mile break in period, the gear lube should be changed. Took this photo when changing the lube.

The Reluctor Ring can be seen next to the Ring Gear. Its wider than the Reluctor Ring used on the carrier with 3.08 gears.

Install Done


Add Drain Plug
To make gear lube changes easier in the future, I added this drain plug kit. Sealed it with 3M 4200 to guarantee against leaks.

The large round washer looking item is a factory installed magnet that collects metal flakes from wear. The new drain plug is below and to the right of the magnet.

Reinstalled the cover and filled the differential housing with about 1.5 quarts of Mobile 1 70-90 Synthetic Gear Lube. Adding a short piece of plastic tube to the snout of the lube bottle makes filling the differential so much easier.

Fill with Lube


Buttoned up
Everything works great, and the Felpro gasket w/silicone sealer has not leaked. A few coats of Rustolium spray paint keeps the cover looking fresh and rust at bay.

In about 30K miles, the gear lube will be changed, and it will be a snap with the drain plug compared to having to remove the entire cover and replace gasket and sealer.

After the gear and differential change, the Firebird had developed very bad wheel hop. After a lot of research, I decided to replace these soft compliant bushings with Moog solid rubber bushings. That completely eliminated wheel hop on hard acceleration. The car also tracks much better on rough or washboard road surfaces, and expansion joints in the highway don't make the car shimmy.

Interesting to note that the original bushings that came out were not worn or damaged and only had about 35,000 miles on them. They were just too soft for the gear change. Solid rubber in the original control arms is the way to go with a street car.

I avoided poly bushings and boxed control arms due to suspension bind, stress cracks in the axle mounts, and cold flow problems with the poly material. The Moog bushings are hard rubber and eliminate problems introduced by poly bushings.

Need bushing Upgrade

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