2nd Gen Non-Engine/Transmission Dana 80 Caps

[SBillinson]

Hi



I bought a used Dana 80 for a dually but noticed when I got home that the pinion would only turn a half turn. I took off the rear cover and noticed that the bolts on the right side of the limited slip housing were rubbing on the bossess on the right cap.



Each of the two caps have 2 bosses or arms on one side. The caps were installed with the bosses pointing inward. I am wondering if the guy I bought the rear from took off the caps for some reason and installed them wrong. There are no markings on the caps to indicate how they should be installed and I can't find pictures or diagrams anywhere to see how the caps are supposed to be installed



What I need to know is whether or not the caps are supposed to be installed with the bosses pointed inward, outward, or in same direction.



Any help would be greatly appreciated.



Thanks



Steve

 

[jrobinson2]

The factory service manual shows a picture of "installation reference letters" stamped in the bearing caps and adjacent gasket surface on the housing.



Jared

 

[Speedo]

The factory service manual shows a picture of "installation reference letters" stamped in the bearing caps and adjacent gasket surface on the housing.



Jared

In other words there will be a letter stamp on each bearing cap one will be vertical and there will be a coresponding vertical letter on the gasket surface next to that cap. The other cap will have a horizontal letter and so on. All of the letters will be the same so you have to pay attention to the orientation of the letter to indicate sides.



Gus

 

[Straight6Jeff]

The caps are on wrong. Also, teh caps are specific ot each side. The housing is honed witht he caps in place, so each cap has to go on teh correct side, or smoked or spun races will result

 

[SBillinson]

Jared



That info was huge! The caps were not only pointed in the wrong direction, but they were on the wrong sides.



I talked to the guy who sold the rear to me and he did say that he took the caps off. Apparently, he wanted to part it out, but didn't know how to take the axles out. He said he took the caps off when the rear was already out of the truck, so the rear was never run with the caps on the wrong way. I am going to change all the bearings and clean it out.



I chamferred the marks on the one cap where the bolt heads were rubbing. Should I magniflux the caps? I hope the caps didn't get distorted from being put on the wrong sides. Any thoughts?



Thanks to everyone for their help.



Steve