Dana 80 failing after less than 115,000 miles?
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.

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"
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.
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.
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.

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

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.
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.
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.
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)
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)

Tobin
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.
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.
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!








