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Well I went and checked the door tag on truck I pulled that 9.5 from axle rating is 6000, which is plenty. I also had a look at 11.5 and 10.5s, but all were pre 2001. The 11.5 is WAY too much! 10.5 pretty reasonable, but in terms of load and duty the 9.5 would be just fine. Lockers/posis...

LOL. I have to match 3.73. No worries.

@Len.Barron, do the 10.5 and 11.5 use the same axle housing with different guts? i.e. is ground clearance the same for both?

Thanks again @Len.Barron Sincerely appreciated. I'll scrap this project, return this 9.5 and go for 11.5. I looked into the Ford, looks like too much trouble due to incompatible wheel bolt circle diameter. Same as luthj, I am using a GMT 800 based front for the 4x4 conversion, and I already...

Thanks @Len.Barron, the detailed info is really helpful, and this info is compelling enough to put this 9.5" on hold. While I don't shy away from doing the work to tune up the pinion and backlash and add the ABS wheel sensors and tone ring, these points are most pertinent to me: -Aftermarket...

luthj, I appreciate your input as always. What you have to say is duly noted and it is an echo of what I just did this week researching the entire local market for GM axles. I made the decision to work with this one with that in consideration. I am however still open to discussion of specifics...

Why? Please be specific.

The smaller inboard plywood disk in the mockup is the tone ring.

Alright! I made a model of the tone ring assembly and it will work. Still have a little dimensional tweaking to do PIc 1- The mockup. Very simple, will amount to 4 parts. in this pic three of the 4; The larger flange mounts to the axle's wheel flange, the inner smaller ring is the tone ring...

Yes I do, but my old eyes don't adjust well to the immediate change when the arc strikes. Especially can't see well when doing inside corners.

LOL, for me it comes down to mediocre welding skills!

Thanks, potentially good call. I should have noted the door tag rear axle weight. Can go back and check soon. Internet info is not excellent regarding axle weight for this 9.5" variant, but some info points at 5000-5500lb. Sprinter's is 5360. Edit: This Sprinter is my cargo van converted to...

I considered three options for adding tone rings and sensors (listed from worst to best): 1: Add a tone ring on the neck of the pinion dust cover/slinger and mount the sensor to a bracket on the diff case. Split this signal into two and feed each to the Sprinter's ESP. This option has a problem...

Figured I'd share a work in progress. I am just getting started and value input! With a few minor differences I am playing along with Luthj converting my van to 4wd. I was salivating over the ARB front locker he installed, but after consideration decided I'd try something different, and it is a...

As part of the 4wd conversion, I am also going to transplant a GM rear axle. These are full floating, no stabilizers/sway bar, control arms etc. The sprinter has a rear stabilizer/sway bar. I am wondering about adding brackets to the GM axle to accommodate these. I also think I have a composite...

Old 208 yoke, works perfectly in the T case, even same size seal. Lucked out finding one in a local parts yard. They are an older model part, the one I found needed some sanding/polishing. Here's one on ebay. And...

9.5 IFS 1350 front yoke https://cmgearworks.com/product/gm-8-25ifs-9-25ifs-pinion-yoke-1350-chevy-2500-3500-4x4-front-axle-8-25-ifs-9-25-ifs-2016-2019/ EDIT: not sure ifthis will work on earlier diffs: specs 2016 up

Hmm, I never heard of this failure in a Sprinter NAG1. I guess with the beefing up of everything else in the drivetrain, and the potential torque 4 wheelin' could become a problem. I don't see and immediate solution though, just something to be aware of?

How so? Clog?

Dang. You're going all out! Alas I can't justify keeping up with the Luths on that one! Envy. Will be interesting to compare cost notes once we are all done.