I was WOT tuning my truck today (closed course) and the tires were breaking loose and spinning at 50mph. The G80 was functioning just fine with both wheels spinning. I noticed a clunking/disengaging sound at a few right hand turns after stop signs. Is this a sign of stress on the G80? What should I look out for before this thing decides to exit the rear cover?

 

I have replaced one b/c of that exact complaint, of course i had to put a factory one back in it but it fixed it.

 

Mine used to clunk hard if I accelerated on a right turnand in reverse on loose ground would clunk so hard I thought I snapped an axle but it seems to be normal behavior for that unit.
Time for you to swap out to a LSD anyway.

 

look for a quality replacement. I will offer this up though: one time I thought I broke the G80 in white1's truck while he was out of town. It was clunking bad on left turns. I babied it home (1/4 mile) and upon tear down I found a couple ring gear bolts loose and backing out.

 

Ditch the G80 and go Tru-Trac Mine puts a smile on my face every time

 

I can't find a trutrac for a 10.5" 14 bolt. I found an Eaton lsd and detroit locker (too agressive). Eaton lsd is $730

 

mine's doing the same thing...i just got back from the mechanic checking it...i was scared is my g80 going bye-bye but he said it was normal...and well now that I read this thread I can see it's normal after awhile...the sound is annyoing though, i'll be changing it soon. the only sound I like my truck to make is exhaust, and the "wara-wara" of the cam

 

There is also a Powertrax no-slip for the 10.5". Will these lockers fit a carrier that originally had a G80 in it or do I need to buy a new open carrier to install with the locker?

 

i busted the G80 in my 04 hd2500 2 times and i replaced it with a powertrax and i wont ever go back oh and it wont fit in the G80 case i went to the junk yard and got an onen carrier out of an old 3/4 ton 4X4 chevy any 10.5 14bolt carrier will work

 

no slip has to be installed in an open carrier, I can tell you from having the powertrax no slip in my truck that it's too aggressive for a daily driven street truck for my taste.... hence why I'm now now running an Eaton LSD.