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Dana 80 failing after less than 115,000 miles?

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Old Feb 11, 2012 | 12:17 PM
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From: Washington state
Dana 80 failing after less than 115,000 miles?

I took my 01 Ram in to the dealer for OLF yesterday. I was told I needed to have my rear diff "rebuilt" or replaced, at a cost of between $3 to $5 grand. Can someone explain to me how the heaviest rear end they make for my truck can be failing when I've hardly towed or hauled with this truck? It is a daily driver with manual transmission. Can't believe I'm getting the real story. Thanks for any info you can offer. Does my truck possibly have this Dana 80 "hybrid" I read about?

sorry, this should have been under 2nd gen heading. my bad.

Last edited by mommak; Feb 11, 2012 at 12:20 PM. Reason: posted under wrong "generation"
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Old Feb 11, 2012 | 12:29 PM
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Run away! Rebuild is no where near that expensive.
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Old Feb 11, 2012 | 12:34 PM
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From: Washington state
Thanks RonA, yeah that's what I'm thinking.
2nd opinion for sure. Could be they think I'm an easy target cuz I'm female? Well, they are sadly mistaken - oh, yes I'm female but I'm a MARINE MOM. Don't mess with Marine moms.
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Old Feb 11, 2012 | 12:35 PM
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From: granite falls washington
Line boring if needed can get a little steep but thats nutz.

Were are you maybe someone can recommend a honest shop.
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Old Feb 11, 2012 | 12:36 PM
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From: lyman, utah
Originally Posted by mommak
I took my 01 Ram in to the dealer for OLF yesterday. I was told I needed to have my rear diff "rebuilt" or replaced, at a cost of between $3 to $5 grand. Can someone explain to me how the heaviest rear end they make for my truck can be failing when I've hardly towed or hauled with this truck? It is a daily driver with manual transmission. Can't believe I'm getting the real story. Thanks for any info you can offer. Does my truck possibly have this Dana 80 "hybrid" I read about?

sorry, this should have been under 2nd gen heading. my bad.
what are the symptoms? i have over 260,000 miles on mine and still going strong
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Old Feb 11, 2012 | 12:43 PM
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What did they say was wrong? I'm assuming the hardening is coming off the gears?
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Old Feb 11, 2012 | 01:29 PM
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From: Hugo,ok.
If it dont howl,growl or make any noise drive it!!!! Be sure to keep it full of the right oil.
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Old Feb 11, 2012 | 02:01 PM
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I've seen rears disintegrate for a couple reasons.

The pinion yoke was removed to fix a seal, and then over torqued, crushing the crush collar, and changing the relationship between the ring and pinion, causing them to wear each other out. Not sure if your axle has the crush collar, so that may or may not be your issue.

The second was the failure to install the differential additive for limited slip rears. The friction modifiers are required for the clutch packs in the diff. Without them, the clutches wear out prematurely.


A good question to answer is the guys asking..... "What is your rear doing and what noises is it making????"

(no snickering guys)
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Old Feb 11, 2012 | 11:21 PM
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From: Longview, Tx
Originally Posted by NJTman

A good question to answer is the guys asking..... "What is your rear doing and what noises is it making????"

(no snickering guys)


too late.
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Old Feb 11, 2012 | 11:28 PM
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I picked up one of those disc D80's for $400.

For $3-5k you could buy the specialty tools, rebuild it, put in a Detroit Locker, and still have money left over.

The Dana 80 is considered 'hybrid' when the vehicle is only a 3/4 or 1-ton truck. The Dana 80's original design is intended for heavier trucks (think F450/550 and similar) which feature bigger wheel bolt patterns necessitated by larger bearings; also heavier axle tubes and axle shafts.
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Old Feb 12, 2012 | 08:59 AM
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From: sheet hole called California
Beware the dealer...

Way back when my truck was young, it had a problem. The dealer told me I needed a transmission and a transfer case.... $8,000.
F U I told them and left.
Turned out it was only a bearing in the Getrag. I saved that paperwork from the Steeler.
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Old Feb 12, 2012 | 11:12 AM
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From: Washington state
wow, thanks for all the tips.
That's just it, there are no symptoms. the mechanic just told me there was a little "play" and that there should be no movement at all when he wiggles the driveline back there. Pardon my terminology, i'm not a mechanic....still learning.
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Old Feb 12, 2012 | 11:13 AM
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From: Orlando, Fl
Originally Posted by NJTman
I've seen rears disintegrate for a couple reasons.

The pinion yoke was removed to fix a seal, and then over torqued, crushing the crush collar, and changing the relationship between the ring and pinion, causing them to wear each other out. Not sure if your axle has the crush collar, so that may or may not be your issue.

The second was the failure to install the differential additive for limited slip rears. The friction modifiers are required for the clutch packs in the diff. Without them, the clutches wear out prematurely.


A good question to answer is the guys asking..... "What is your rear doing and what noises is it making????"

(no snickering guys)
If it is just the clutch packs, the LS won't work. That is a simple driveway fix with a pack of new frictions and steels, gasket, and fluid.

Tobin
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Old Feb 12, 2012 | 12:24 PM
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I don't know where you are in WA but if its near me I'd avoid the dealer for anything. too many heavy equipment guys with shops around that can do the work for a lot less, even on the side and hungry to work.

I'd get a couple more opinions, as mentioned you could probably find a used one and get it put in for less than a grand.
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Old Feb 12, 2012 | 02:30 PM
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From: Yuba city Kalifornia
you are in danger RUN AWAY FAST ! every drive line has to have some back lash in it or its to tight! I have heard of DANA 80 with 1,000,000 miles on them and still going. my DANA 70 has 800,000 miles on it and still going!
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