Dana 80 Differential Specs
Manufacturer: |
Dana Holding Corporation |
Applications: |
• 1994 - 2002 Dodge Ram 3500 |
Type: |
Full floating rear differential |
Ring Gear Diameter: |
11.00" |
Pinion Shaft Diameter: |
2.00" |
Pinion Shaft Spline: |
37 spline |
Axle Tube Diameter: |
4.00" |
Axle Shaft Diameter: |
1.50" (35 spline), 1.58" (37 spline) |
Axle Shaft Spline: |
35 spline (1.50" axle shaft), 37 spline (1.58" axle shaft) |
Max GAWR: |
11,000 lbs |
Gear Ratio Range: |
3.23 : 1 to 5.38 : 1 |
Fluid Spec: |
• Dodge - SAE 80W-90, 75W-140 suggested as a heavy duty alternative Recommend Amsoil 75W-140 Severe Gear synthetic gear oil for all applications |
Fluid Capacity: |
Ford calls for 4.2 quarts, Dodge calls for 3.4 or 5.0 quarts depending on the application - always fill differential until oil reaches the fill plug level. Limited slip differentials may require an additive, refer to owners manual. |
Differential Cover Gasket: |
|
Differential Cover Upgrade: |
Dana Spicer 10023537 (heavy duty OE pan upgrade w/ drain plug) |
Dana 80 Gear Oil Recommendations
Diesel Hub recommends the following Amsoil gear oils for all Dana 80 differentials
Amsoil 75W-140 Severe Gear synthetic gear oil
Preferred viscosity for all applications
Amsoil 80W-90 Severe Gear synthetic gear oil
Acceptable viscosity per OE requirements
Amsoil synthetic "Severe Gear" gear oil benefits include:
• Extreme pressure, anti-wear formula provides maximum protection against wear, pitting, and scoring due to metal-on-metal contact
• Superior performance and stability in extreme hot and cold operating conditions
• Long lasting proprietary formula resists degradation from mechanical and thermal breakdown
Dana 80 Differential Oil Change Procedures
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• Place the transmission in park (automatic) or in gear (manual) and set the parking brake.
• The Cardinal rule - always make sure you can remove the fill plug before draining the differential and rendering the truck inoperable. Remove the fill plug using a 5/8" square drive socket. If it won't budge, consider your removal options before draining the oil.
• The Dana 80 differential cover is held in place by (10) bolts. Remove (8) of the bolts and generously loosen (but do not remove) the two top bolts such that the cover will be held in place while the fluid drains.
• Use a flathead screwdriver, putty knife, or similar tool to break the seal between the differential housing. Be cautious as not to mar the machined surface of the differential housing.
• Allow the differential to drain completely, then remove the remaining cover bolts and then the entire differential housing cover.
• With the cover removed, use a lint free rag to completely remove any remaining fluid from the differential.
• Inspect the bottom of the differential housing for any metal particles/debris, which may indicate severe wear and/or damage.
• Using a plastic bag to protect the inside of the differential housing from debris and contamination, thoroughly clean the differential housing of any remnant sealant and/or gasket material. Lightly spray a lint free rag with a solvent (brake cleaner, carb cleaner, etc) and clean the surface of any oil residue. Do not spray solvent directly on the housing or allow any inside the differential housing.
• Thoroughly clean the differential housing cover, removing any traces of previous gasket material and/or sealant. Remove any oil from the seating surface with a solvent (brake cleaner, carb cleaner, etc). Remove any debris from the inside of the cover once it has been cleaned.
• Clean the cover bolts of any sealant and oil.
• The Dana 80 differential does not require a gasket - you can use an oil resistant RTV silicon alone, or you can use a gasket and RTV silicon. This is somewhat a matter of preference and experience, but we've opted to install a gasket against the differential housing and use silicon to seal the cover. Whichever route you decide, lay a continuous bead of oil resistant RTV silicon around the entire mating surface of the housing (3/16" - 1/4" bead is sufficient) and around the bolt holes. You may also choose to place a dab of silicon on each of the cover mounting bolts.
• Reinstall the differential housing cover. Snug all bolts in a star pattern, alternating from side-to-side. Finally, torque the cover bolts to 30 lb-ft in an alternating pattern.
• Allow the silicon to cure per the manufacturer's recommendations (24 hours is relatively common if no time interval is given).
• Remove the square drive fill plug and add fluid until it reaches the fill plug level and begins to run out of the cover. Replace the fill plug (torque to 25 lb-ft), test drive the vehicle, and check for leaks.