Power Wagon Registry

Hello,

I am a new owner to a 2005 Power Wagon in Manitoba Canada!

I bought this truck as we farm out in the prairies and my Chevy started to ask for an early retirement.

I’ve owned the truck for a little over a week now and already kinda broke it I was hauling snowmobiles and after unloading them and separating the trailer from the truck I wanted to see if I could make it through the snow ditch with the truck. Well, I couldn’t I switched the truck to 4L and engaged the Axle Locks both rear and front. I then tried to Austin powers my way out of the ditch (back and forth) with the help of manually shovelling the snow away but eventually called it quits after an hour or so and had the truck winched out by a friends big ol 5500.

Damage done from this adventure:

Axles not unlocking / currently in the shop and removed the front diff plate to see metal shaving build up on the magnet. Cleaned the magnet but haven’t tested the function of the lock yet. Rear diff to get opened and cleaned as well.

Power steering failing / currently with the truck not moving it is almost impossible to turn the wheels. Unless you are very very strong. At 10 - 20kms steering is much easier but no where near right. Power steering is making a lovely whine noise. Will check fluid level, and see if I caused something to come loose and it sprung a leak.

Other than that - the truck is in the shop and I’ll be spending some time cleaning, repainting and servicing the suspension components, new spark plugs, and whatever else I find along the way.

I’m looking forward to reading posts from other owners to learn what I can about this truck.

If anyone is local in MB Canada with the same model truck let me know!! Maybe we can get together and I can pick your brain.

See ya around - Joe 05BigRed

Welcome to the forum! Enjoy !!! Recommend you reach out to Retired BLM Rig in Board Index/Vendors/Abel Products. While lots of the members are very knowledgeable have found him to be a very knowledgeable resource on these types of questions. Leave him your contact info & he will get back to you. Am sure he’ll know the right questions to ask to help I’d the issues. Our 2005’s parts are getting hard to get & he also is a good resource to help w that. Other members are also quite knowledgeable & helpful but may take a bit longer to respond. Good luck & keep us posted!

Welcome to the group!

Sounds like you had a rough time in the ditch... The winch is usually the go-to when you get stuck like that and even your lockers aren't getting you free - but i see you're missing the winch

Welcome to the forum.

Thank you for the welcomes.

Replaced the power steering pump and ended up just unplugging the sway bar connector which after a few weeks the axles finally disengaged. I'm nervous to try and lock them up again, so I'm just not using the locks until I get around to doing a fluid change of the diffs and I'll pull them out to see if they are broken or not.

Other than that, I had my catalytic converters stolen which is a common thing in the area. Ended up just putting exhaust piping in place of where the cats would be and had the truck tuned, and the O2 sensors deleted.

Looking forward to spring and summer in my area. It's almost mudding season!!! Time to get this truck nice and dirty.

05BigRed wrote: ↑

Mon Apr 01, 2024 12:00 am

Thank you for the welcomes.

Replaced the power steering pump and ended up just unplugging the sway bar connector which after a few weeks the axles finally disengaged. I'm nervous to try and lock them up again, so I'm just not using the locks until I get around to doing a fluid change of the diffs and I'll pull them out to see if they are broken or not.

Other than that, I had my catalytic converters stolen which is a common thing in the area. Ended up just putting exhaust piping in place of where the cats would be and had the truck tuned, and the O2 sensors deleted.

Looking forward to spring and summer in my area. It's almost mudding season!!! Time to get this truck nice and dirty.

Do you use the truck on the road? In the states, we can't get away without having the Cats and the O2 sensors... I suspect you're enjoying lots of power but single digit mpg now

Bill2014 wrote: ↑

Tue Apr 02, 2024 3:43 pm

05BigRed wrote: ↑

Mon Apr 01, 2024 12:00 am

Thank you for the welcomes.

Replaced the power steering pump and ended up just unplugging the sway bar connector which after a few weeks the axles finally disengaged. I'm nervous to try and lock them up again, so I'm just not using the locks until I get around to doing a fluid change of the diffs and I'll pull them out to see if they are broken or not.

Other than that, I had my catalytic converters stolen which is a common thing in the area. Ended up just putting exhaust piping in place of where the cats would be and had the truck tuned, and the O2 sensors deleted.

Looking forward to spring and summer in my area. It's almost mudding season!!! Time to get this truck nice and dirty.

Do you use the truck on the road? In the states, we can't get away without having the Cats and the O2 sensors... I suspect you're enjoying lots of power but single digit mpg now

Ended up getting an OE spec exhaust replacement. Was worth doing in my opinion. Much quieter and peaceful to drive.

My front differential ended up blowing up this past Sunday. Was cruising at 125kms for 2ish hours, ended up making it into town and after accelerating from a stop at a light I heard the grinding noise. Drove to the closest shop and they said a replacement would be around the $3500 mark.

I plan to take the diff cover off and see what actually broke inside. Fingers crossed its just the actuators for the axle locks and I can remove the broken bits, clean the diff, and off I go.

Not sure though.... We will see.

Good luck ! Hopefully that will be the only issue for you!

Update:

Spent the time and did a front differential rebuild minus the axle lock pieces. They were in fact what failed in my differential. So I replaced all the bearings and seals for my diff and reassembled.

Also, learned that my front driver side caliper was seizing on one piston. I have a new caliper coming in on Monday to replace the seized one. FYI the pistons are very brittle! If you try to pry it free with a pry bar its very easy to break haha. Lesson learned.

HOPEFULLY! Monday evening I'll be able to drive Big Red once again as it has been quite some time since I've parked it for the differential repair. I just wont have front Axle Locks anymore.

Does anyone know of a good aftermarket option that's manual locks? Where you can lock them at the wheel bearing hub?

05BigRed wrote: ↑

Sat Jun 22, 2024 6:57 pm

Update:

Spent the time and did a front differential rebuild minus the axle lock pieces. They were in fact what failed in my differential. So I replaced all the bearings and seals for my diff and reassembled.

Also, learned that my front driver side caliper was seizing on one piston. I have a new caliper coming in on Monday to replace the seized one. FYI the pistons are very brittle! If you try to pry it free with a pry bar its very easy to break haha. Lesson learned.

HOPEFULLY! Monday evening I'll be able to drive Big Red once again as it has been quite some time since I've parked it for the differential repair. I just wont have front Axle Locks anymore.

Does anyone know of a good aftermarket option that's manual locks? Where you can lock them at the wheel bearing hub?

If you are looking for axle differential locks, I can't imagine a scenario where that would be done at the hubs...

As far as locking differential options, I know that Eaton and ARB make selectable differential locks, you'll have to do a search and see if there are options...

05BigRed wrote: ↑

Sat Jun 22, 2024 6:57 pm

Update:

Spent the time and did a front differential rebuild minus the axle lock pieces. They were in fact what failed in my differential. So I replaced all the bearings and seals for my diff and reassembled.

Also, learned that my front driver side caliper was seizing on one piston. I have a new caliper coming in on Monday to replace the seized one. FYI the pistons are very brittle! If you try to pry it free with a pry bar its very easy to break haha. Lesson learned.

HOPEFULLY! Monday evening I'll be able to drive Big Red once again as it has been quite some time since I've parked it for the differential repair. I just wont have front Axle Locks anymore.

Does anyone know of a good aftermarket option that's manual locks? Where you can lock them at the wheel bearing hub?

Was it the locker dog clutch gears inside the carrier assembly that failed, or was it the the electric actuator on the outside?

Retired BLM Rig wrote: ↑

Mon Jun 24, 2024 8:22 pm

05BigRed wrote: ↑

Sat Jun 22, 2024 6:57 pm

Update:

Spent the time and did a front differential rebuild minus the axle lock pieces. They were in fact what failed in my differential. So I replaced all the bearings and seals for my diff and reassembled.

Also, learned that my front driver side caliper was seizing on one piston. I have a new caliper coming in on Monday to replace the seized one. FYI the pistons are very brittle! If you try to pry it free with a pry bar its very easy to break haha. Lesson learned.

HOPEFULLY! Monday evening I'll be able to drive Big Red once again as it has been quite some time since I've parked it for the differential repair. I just wont have front Axle Locks anymore.

Does anyone know of a good aftermarket option that's manual locks? Where you can lock them at the wheel bearing hub?

Was it the locker dog clutch gears inside the carrier assembly that failed, or was it the the electric actuator on the outside?

It was the clutch gears on the inside that blew up into lots of little pieces.

05BigRed wrote: ↑

Sat Mar 15, 2025 8:48 pm

Retired BLM Rig wrote: ↑

Mon Jun 24, 2024 8:22 pm

05BigRed wrote: ↑

Sat Jun 22, 2024 6:57 pm

Update:

Spent the time and did a front differential rebuild minus the axle lock pieces. They were in fact what failed in my differential. So I replaced all the bearings and seals for my diff and reassembled.

Also, learned that my front driver side caliper was seizing on one piston. I have a new caliper coming in on Monday to replace the seized one. FYI the pistons are very brittle! If you try to pry it free with a pry bar its very easy to break haha. Lesson learned.

HOPEFULLY! Monday evening I'll be able to drive Big Red once again as it has been quite some time since I've parked it for the differential repair. I just wont have front Axle Locks anymore.

Does anyone know of a good aftermarket option that's manual locks? Where you can lock them at the wheel bearing hub?

Was it the locker dog clutch gears inside the carrier assembly that failed, or was it the the electric actuator on the outside?

It was the clutch gears on the inside that blew up into lots of little pieces.

Allstate Gear shows that they have the complete carrier assembly with spider gears. AAM #40048164 (replaces AAM #40047279). If you need the locker actuator, it's available separately, AAM #40160105.

I’m in a bit of a battle convincing myself to buy new front e lockers. I’d need to pick up the wiring and sensors as well as mine have been cut. Even my connector that goes to the sway bar needs to be replaced. Right now I just have it unplugged and drive without it all.

Bill2014 wrote: ↑

Mon Jan 22, 2024 10:13 am

Welcome to the group!

Sounds like you had a rough time in the ditch... The winch is usually the go-to when you get stuck like that and even your lockers aren't getting you free - but i see you're missing the winch

I’m assuming my front bumper was changed with a regular 2500s bumper and the winch once removed way back. I’d like to get another winch on the truck though. One day, I’ve now pulled myself out of a few situations with tractors where a winch would of been extremely handy to have.

The Power Wagon front bumper is the same as a regular 2500
Look behind the opening in the bumper to see if the winch mounting plate is still there

gtomike60 wrote: ↑

Sun Mar 30, 2025 5:07 am

The Power Wagon front bumper is the same as a regular 2500
Look behind the opening in the bumper to see if the winch mounting plate is still there

Mounting plate is gone





Also shot of the broken plug for the sway bar

My system bypasses all the factory wiring and comes complete with a new harness. No need to repair/replace the sway bar or locker connectors.

Retired BLM Rig wrote: ↑

Mon Mar 31, 2025 10:59 am

My system bypasses all the factory wiring and comes complete with a new harness. No need to repair/replace the sway bar or locker connectors.

Absolutely wonderful. Last item would be to get a new front E-Locker then and she’s back to normal but better 🥹