Dana 80 broken

[ironforger]

That looks beautiful. Outstanding work.

 

[SAndreasen]

I would be leery of doing such axle repairs while its still on the truck because axle alignment is critical for bearing wear and longevity. For this reason, when doing anything extensive which involves removing or moving bearing surfaces then its best to remove the differential and all internal components and use a jig to assure everything remains aligned. In a pinch if you're stranded on the road is acceptable but certainly not what I'd suggest as normal...

Those guys know what they are doing and they repair axles that haul 20 times more than a little dodge truck

 

[DMather]

I just had my drivers side spindle replaced a month ago, same day, by Axle Surgeon (in my case, of Oklahoma....where the axle broke and destroyed the spindle) Axle Surgeon franchises are all over and their rates are very reasonable.
Have 5000 miles on it already and it's running sweet (and my boost is running about 1 psi lower overall, leading me to think the wheel bearing was in distress for a while.)

 

[ironforger]

I just had my drivers side spindle replaced a month ago, same day, by Axle Surgeon (in my case, of Oklahoma....where the axle broke and destroyed the spindle) Axle Surgeon franchises are all over and their rates are very reasonable.
Have 5000 miles on it already and it's running sweet (and my boost is running about 1 psi lower overall, leading me to think the wheel bearing was in distress for a while.)

Wow @DMather , thats great you were able to get it fixed same day! How fast were you going when the axle broke? Were they the original factory wheel bearings? How about the passenger side bearings, did the Axle surgeon inspect them?

 

[SnoKing]

The early 2nd gens had smaller weaker brakes. 2000 on up were the better brakes and all manual transmission 2500, and all 3500, had the larger brakes.
My 2500 has the same brakes as the 3500 came with. And my stock style brakes will bring this 4 ton truck to a very abrupt stop if I need it to.
That said, the hydroboost system health is directly related to the performance of the brakes too. So a struggling hydroboost system will result in a weak braking system forcing the driver to exert more pedal pressure. Keeping the PS clean and run synthetic is important.....but most people never even bother to look at the PS fluid.

Manual 2500's and 3500's had Dana 80. Auto 2500's had Dana 70's. I think. Then there was the HY-35 and HX-35 different of the later 2nd gens, with auto's getting the HY-35.

 

[KATOOM]

Manual 2500's and 3500's had Dana 80. Auto 2500's had Dana 70's. I think. Then there was the HY-35 and HX-35 different of the later 2nd gens, with auto's getting the HY-35.

Correct..
And the 1998.5 - 2000's automatic transmission trucks had the 12cm HX but was switched to the 9cm HX from 2000 - 2002 for faster low load spooling.

 

[SAndreasen]

I just had my drivers side spindle replaced a month ago, same day, by Axle Surgeon (in my case, of Oklahoma....where the axle broke and destroyed the spindle) Axle Surgeon franchises are all over and their rates are very reasonable.
Have 5000 miles on it already and it's running sweet (and my boost is running about 1 psi lower overall, leading me to think the wheel bearing was in distress for a while.)

what do they charge to do the repair

 

[SnoKing]

Correct..
And the 1998.5 - 2000's automatic transmission trucks had the 12cm HX but was switched to the 9cm HX from 2000 - 2002 for faster low load spooling.

My PDR35-12W (modified HX35) spooled very similar to the OEM HY35, however the PDR cooled EGTs better.

 

[DMather]

Wow @DMather , thats great you were able to get it fixed same day! How fast were you going when the axle broke? Were they the original factory wheel bearings? How about the passenger side bearings, did the Axle surgeon inspect them?

I had just filled the tank in Oklahoma City and as I merged onto 44 westbound the truck lurched like I had hit something in the road. (it was dark) Then everything went back to being normal. Locked in at 77mph and was running smooth for 25 miles, at which point the drivers side axle, that had been running metal on metal with the spindle, broke and I got to side on the side of the turnpike for 3 hours waiting for a tow. A local shop made a "field repair" in an attempt to get me back home but it only held for 50 miles. That's when I called Axle Surgeon. AAA towed (flatbed) the 40 miles to their facility and they met me after hours on a Sunday. The took time to pull the axle on the drivers side and found the new bearings trashed. My wife and I had driven out to bring the truck home, so we left the truck in their care and continued on home. Got a call the next afternoon that the truck was repaired. (had I known, we would have just stayed in a motel for the night)

Yes, they were the original bearing. (435,000 miles)
Yes, they inspected the passenger side and I had them replace the bearing and they found 5 sheared bolts on the hub. They replaced the hub with a used but serviceable one.

Truck now has 445,000 miles and no problems on the rear end.

The spindle repair is 1100. My total tab with spindle repair, two sets of bearings, 2 used hubs, flush of axle, new fluid and labor came to 2500.