[HaulinDuals]

Ok, so this ever-so-occasional CLUNK coming from somewhere underneath. I knew it couldn't be tranny or u-joints, but possibly u-joints for the 4x4 half. Only a day or two, a louder clunk once when backing up and clunk-clunk-clunk as driving (slowly). Limped it home 20-25mph. Jacked it up and found the noise coming from the rearend. /ubbthreads/images/graemlins/crazy.gif Opened it up and found about 4 pieces of a small gear and a bit of damage to the ring and antilock ring. Haven't disassembled yet, so I am guessing that it was one of the pinion gears.

Two questions:

First:
What did I do to cause it? Drive too fast/hard? /ubbthreads/images/graemlins/rolleyes.gif Torque it somehow? /ubbthreads/images/graemlins/eek.gif Using 4x4 in less than idea conditions? /ubbthreads/images/graemlins/blush.gif Not a big deal,just wondering. /ubbthreads/images/graemlins/shrug.gif

Second:
Recommendations from motorheads for replacement. Since it is a 2001 Dually, it has a Dana 60 4:10. I wouldn't mind lower rpms at highway speeds, but I'd hate to sacrifice too much low-end. I pull a 25ft boat in the summer months. It has a Suncoast trans with a really mean shift. Any suggestions for beefing the rear since I have to replace things. I could possibly swap it for a rebuild or I could replace the internals. What do you suggest?

THANKS!

 

[Sapps]

Wouldnt that be a Dana 80 in the rear of the dually? My 02 was. May want to double check that. /ubbthreads/images/graemlins/shrug.gif

 

[redfishman17]

Best case scenario is it is just your pinion bearings, to tell that just grab the u-joint in front of the gear case and see if it has any play and you can hope it didn't do to much damage to the ring and pinion. If the clunk occurs ever tire rev then its deffinately your ring gear. Most cases you will snap a couple of gears off of the ring before it will happen to the pinion. Otherwise it could be your spider gears. In that case I would get a locker. /ubbthreads/images/graemlins/biggrin.gif and if its a dualie its a dana 80

just my $.02

 

[HaulinDuals]

Oh, sorry - I thought the "60" in the tag number meant it was a 60. The gear was sitting in the bottom of the housing, and the ring and anitlock ring already have some damage. Not heavy, but enough to have to be replaced. Maybe a bearing went first? Not sure what can cause a pinion gear to break into several pieces.

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

Subject changed.

 

[smorris]

Re: UH OHHHH - Dana 80 rearend is TOAST!

Call Randy's ring and pinion. Under $200 for new kit to rebuild limited slip, and spider gears. As for the ring and pinion thats another story. Dont forget to replace that toner ring for the abs brakes, and speed pickup to work right.

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

aaHAAA - that explains why the speedo started jumping around some too.

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

OK, been researchin' a little. I think I have a Dana Spicer 80 4:10 with 11.25" ring and 10-bolt cover, according to my manual and associated diagrams.

<u>Damage visible so far just taking the cover off:</u>
<ul type="square"> [*]Chips on outer edges of some ring teeth. Maybe out of the contact patch and could be gound?

[*]Missing a few abs ring teeth - will have to be replaced.

[*]And then there is that gear that was at the bottom of the housing - obviously it has to be replaced and may have caused other damage inside. [/list]
How can I determine (prior to disassembly) if I have 35 or 37 spline? And if you have used a Detroit or Arb locker, please chime in with some opinion fodder? Also, with 175K+ miles, would there be enough wear to automatically warrant replacing the ring when doing this, or would that be a measure and observe wear thing? Thanks.

 

[trick76cj5]

Re: UH OHHHH - Dana 80 rearend is TOAST!

It's a full floater, so pulling the axle out should be relatively simple. Unbolt the plat at then end of the axle and slide the shaft out, the hubs will hold the truck up so it should be simple (unless you have center caps).

 

[klhansen]

Re: UH OHHHH - Dana 80 rearend is TOAST!

If there was a (whole??) gear laying inside the case, it's probably a spider gear, and that would mean the shaft has broken. In any case, you'll probably need a differential gearset (side gears and spiders). Going with a locker at this point wouldn't be a bad option IMO.

You'll have to check closely whether those ring gear chips got into the contact pattern. I'd be guessing there may be a few chips in the pinion gear as well, but you won't know that till you pull the diff.

As far as telling whether you have 35 or 37 spline, just pull an axle shaft and count them. You don't have to go any further than that in disassembly to tell. And that's just a few bolts and a prybar. Don't even have to jack up the truck or take any wheels off. /ubbthreads/images/graemlins/laugh.gif

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

There was a whole gear laying there. I'm sure that was what chipped the ring, since there was a piece of it caught in the inner (non-toothed portion) of the ring. Pinion may or maynot have been hit. Sounds easy to pull a shaft - I'll do that and check it out.

 

[arisley]

Re: UH OHHHH - Dana 80 rearend is TOAST!

That is what got me to this site. I am a poor boy and just cleaned everything out and buttoned it up and filled it up, been running since, forgot all about it (ostrich approach). Looking for a used rear end I can afford all the time.

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

Well, I got the WD-40 and Duct Tape ready to go! I noticed that it still turns fine after removing the ofending (missing) gear. Are you telling me it is still driveable? I guess so since I drove it home. That would solve some problems for a few days - especially given that it is a weekend. What about towing and loads? That would crack me up if you could remove an appendix, er, I mean a gear and keep driving!! /ubbthreads/images/graemlins/eek.gif

 

[redfishman17]

Re: UH OHHHH - Dana 80 rearend is TOAST!

By no means I wouldn't drive it. That could develop into a big problem real quik. If your doing alot of hauling, I take back my recomendation of a locker. How big are the chips off of your ring gear? I would say if they are small (smaller than a pea) you might be ok, but very temporary.

So it was the spiders that blew out. This is what I would do ONLY if you had plans for getting a whole new rear axle and ONLY if you absolutly needed to drive the truck. I used to have a pair of jeeps that had the rear differentials welded, these jeeps were used as swamp buggies strictly. We completly welded the spider gears together, we used quite a few sticks and made sure it wasn't going to come apart. It actually worked as an effective locker for many many years, until I sold them. The only problem for doing it this way is I don't know how it would hold up at highway speeds, unless you had an unusual gift of being able to balance it as you welded it. This would be very risky if you were making a trip down the interstate but for slow speeds around town you might be fine. I wouldn't do any doughnuts on pavement, even though with a locker it is very fun. /ubbthreads/images/graemlins/biggrin.gif

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

My towing is mostly summer with a 25ft boat (only about 8K load). Sometimes to Cumberland in KY from central OH. I was wondering if locking on a ramp would be better than using 4WD. If I got a locker, it would be mostly for when I get out in the fields at the farm - sometimes those donuts with snow flying high are fun. Or, I mean so I've heard. /ubbthreads/images/graemlins/rolleyes.gif

 

[redfishman17]

Re: UH OHHHH - Dana 80 rearend is TOAST!

Ideally an air locker would be the ticket in that case, so you have the selection. I don't have a locker on my current truck but I wish I did. I have done many one-wheel-peels on the boat ramp before, but I don't mind putting on a smoke show for all the pretty ladies. /ubbthreads/images/graemlins/smokin.gif

 

[HaulinDuals]

Re: UH OHHHH - Dana 80 rearend is TOAST!

Randy's looks like a cool site. Thanks for that lead.

Got the housing cleaned out and confirmed that it was a spider gear completely gone out of the diff. housing. I put 'er back together and have to wait for the seal to cure before putting lube back in. Also popped some new brake pads on the backside since I was workin back there and they were needed before the rear popped. So . . . good to go for a short while as I check out lockers and such.


Does anyone know for sure if the Dana 80 rear takes friction modifier? My manual says a few other types do (such as a 70), but doesn't look like the 80 is s'posed to have it.

 

[klhansen]

Re: UH OHHHH - Dana 80 rearend is TOAST!

I'd really baby that thing with only one spider gear in place. You only have half of the original spider gears, so the side gears will be loaded on one side only. No one-wheel peels or even tight turns under power, or you might just blow the whole thing up. I'd even avoid ANY WOT runs.

[ QUOTE ]
I used to have a pair of jeeps that had the rear differentials welded, these jeeps were used as swamp buggies strictly. We completly welded the spider gears together,

[/ QUOTE ]
aka Lincoln Locker after the guys that manufacture welders. /ubbthreads/images/graemlins/wink.gif