Got my Mag-Hytec rear diff. cover installed today on my Dana 80 hybrid. Not too bad of a job. Hardest part was getting the old cover off. Get a gasket scraper like the instructions say and it will go much easier. I was almost directly underneath it when I was finally able to pry the stock cover off, not sure how much gear oil I ingested, is that stuff toxic? Had a few letters stamped in the mating surface but they were not too deep. Still, as a precaution, I put a thin layer of Permatex Ultra Black over the letters and then installed the cover.
I put about 7 2/3 qts. of Mobil 1 75W90 in it. I also bought some friction modifier for my limited slip, but I did not add it yet. The Mobil 1 website says that the Mobil 1 works with limited slips without the need for additive, but IF you hear chattering, go ahead and put some in. I will wait and see.
I am really glad I made this mod. I can't see having to pry that stupid cover off everytime I want to change the fluid.

~Rob

 

I was looking into getting one for the diff and trans. The local dodge dealer wants an arm and a leg for them. Like 340 for the diff and 360 for the trans. I just laughed and baught the **** ATF +4 that I needed. What did you pay for the diff cover. I think that Mag-Hytec has them for like 250 each on there site.

 

Hope you mean 7+3/4 pints....cause MINE only holds 4 qts???

Glad you had no major trouble....assume your just kidding about swollowing some....but sounds like you gargled a bit.
RJ

 

The instructions said that it should take about 8 quarts to fill up. I believe the owners manual (out in the truck now, so I can't check it) calls for about 6 quarts if you have the stocker. I am assuming you have the Dana 70 because you have an auto, don't know if there is any difference in fill amounts between the D70 and D80 * edit: see a few posts below, there is a 2 qt. difference
I spit out anything I got in my mouth.
For anybody that is thinking of doing this, I forgot to mention, I have the factory rear sway bar and did not have to move it to install the Mag-Hytec. I thought I would, but I was able to wiggle it in there somehow.

~Rob

 

Hows the fit with the spare? Maybe its only a short bed issue but I thought I read that the Mag-Hytec could hit the spare.

 

No problems at all. I wondered about that as well at first. I have a 4x4 Q/C SB and am running a 285/75/R16 as my spare (245's and 265's came from the factory). Never even came close. I didn't have to drop it either to get the new cover on. I was glad, as getting the spare back up and fitting is a pain in the rear, since it is bigger than either factory spare.

~Rob

 

RJ,
You had me worried for a while that I overfilled my diff. but I went back and checked the dipstick today and the level is just below the "Max Full" line on it. I also checked the install instructions again and they definitley say "approximatley 8 qts". The directions are here, line 13 of the install instructions is what I looked at: Dana 80 install directions

I checked the install instructions for the Dana 70 Dana 70 install instructions and they state in line 13 that "approximately 6 qts is required".

~Rob

 

Yep, mine holds eight quarts too.

 

I paid $235 + tax for it. Seems that that is the price just about anywhere I looked.

~Rob

 

Sorry for the false alarm. Forgot you had a Dana 80. Was thinking auto's and a Dana 70!

RJ