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Dana 80 failing after less than 115,000 miles?

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Old 02-11-2012 | 12:22 PM
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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?
Old 02-11-2012 | 01:31 PM
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I have a 2001.5 with 6 speed manual. Towed 144,000 miles all over the
Western U.S. From 8800' to below sea level. From a high of 112 to 28 degree
temps. Never have had a problem. Just had a limited slip put in last week. I think a complete rebuild at an independent shop would be under $1000
Old 02-11-2012 | 01:34 PM
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Did you replace the fluid at the specified intervals? Also, one wheel spin-outs will shorten the life of them substantially.
Old 02-11-2012 | 02:32 PM
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Dealers......Why did they say you need a overhaul?? Whats the problem with the rear end?? Is it noisey??? Or are they trying to make a easy 3 to 5 grand....Which is just nuts for a price..

If you went in there not noicting any problems with your diff....Run away..
Old 02-11-2012 | 02:41 PM
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Originally Posted by Diesel Dave2
Dealers......Why did they say you need a overhaul?? Whats the problem with the rear end?? Is it noisey??? Or are they trying to make a easy 3 to 5 grand....Which is just nuts for a price..

If you went in there not noicting any problems with your diff....Run away..
Agreed. Have someone else look at it. That being said, ANY mechanical device can wear out. It has little to do with how heavy it is- parts wear out, regardless. It could have initially been set up wrong, or gotten water in the oil, or have a bad bearing, or suffered in impact (like a stump, etc.- I'm just giving hypotheticals), etc. If it moves, it wears.
That price is high- never have that kind of work done at a dealership. If it is bad, check www.car-parts.com, and look for a low mileage used one. Or get it rebuilt- you can do better than those prices.
Old 02-11-2012 | 02:43 PM
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"Thanks for any info you can offer"

1st thing that comes to mind is running different size rear tires with the LS.

2nd thing is not changing diff fluid and towing or running heavy. Forget what the book says and change the fluid every 15K if towing or hauling heavy. Every 30K for everyone else. There is no such thing as "forever" lube.

3rd thing is a dishonest dealer - I would pay no money until I get specifics as to what is damaged or worn. If it's just the LS, have an aftermarket LS installed by a shop that specializes in diff work. The new Eaton gear drive LS looks like a winner to me. I would replace with a salvage diff rather than pay the dealer. There are tons of Dana 70/80's out there.
Old 02-11-2012 | 03:13 PM
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275,000 miles on my D80.And did a reference check and its still orginal..I did fuild changes and had to speedy sleeve both axle housing,new seals and new bearings,which I did as a PM...My gears are still prefect and my LS still works...
Old 02-11-2012 | 11:59 PM
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Here's an example of easy to find Dana 80's. Not mine, just an example of what's out there. Disc brakes too...

http://www.ebay.com/itm/2001-Dodge-R...sories&vxp=mtr
Old 02-12-2012 | 10:33 PM
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Oops....double post.....
Old 02-13-2012 | 07:35 AM
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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?
If it is true and it needs rebuilt, I'd say you have a lube failure. What was done as far as lube changes over the years?
Old 02-14-2012 | 05:41 PM
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Originally Posted by j-fox
If it is true and it needs rebuilt, I'd say you have a lube failure. What was done as far as lube changes over the years?
after all the responses and the little i've learned in the last few days, that question also comes to mind. I've trusted them to lube my truck as needed, and if it hasn't been getting what it needs, that would be my fault for being ignorant.
The mechanic wrote the "diagnosis" as a "loose rear pinion". They told me to replace that part it's $1600 just for the part, and hours worth of labor to tear down and put back together. Thats when they said it would be more cost effective to replace the entire rear differential - $3000 for the component, and approx. $1000 for install. But it comes with a 3 year - 100,000 mile warranty.
I'm now thinking if these guys I've met that work on my truck can do this, so can I. It's surely not rocket science because these guys are obviously not the sharpest knives in the drawer. How hard can it be to replace a pinion? (I don't know what one is) The hard part would be getting my truck up in the air to do it.

in addition, there is no noise or vibration that I've noticed coming from there, and I pay pretty close attention to my "baby".
Old 02-14-2012 | 05:48 PM
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I not attempting to be rude- if you don't know what a pinion is, you definitely won't be replacing it yourself. Few things on your truck are as critical to set up as a ring and pinion.
You are being jerked around, though. You can buy a new ring and pinion for less than $400 from Rockauto.
Now, what you could do yourself is to swap one axle for another one- that can be done in less than a day. But first, you definitely need a second opinion.
Old 02-14-2012 | 05:53 PM
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i was pretty much joking on the replace it myself. I just can't believe that on this heavy of a truck that something like this would be worn out already. How do I find out for sure what rear end my truck has in it?
Old 02-14-2012 | 06:10 PM
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Originally Posted by mommak
i was pretty much joking on the replace it myself. I just can't believe that on this heavy of a truck that something like this would be worn out already. How do I find out for sure what rear end my truck has in it?
all manual trans and 3500s have dana 80 auto 2500 have dana 70s
Old 02-14-2012 | 07:57 PM
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no noise or vibration ?????..Tell then the pinion in their head is loose...Get out of there...By you post...they are trying to make a quick buck...And a big one at that..If there is no cluck or noise...Its a prefect diff..Have they showed you this side to side play??? Or are they going to show you the play when they twist the drive shaft...which is normal...


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