They should have used the manual.

[2Farr]

Ever since I purchased my 99 3500 the rear axle didn't quite act right. It has a Track lock unit in it but acted like a open diff. The other day while backing my Fifth wheel in to the driveway I felt a bang from the rear end. It needed a diff lube change any way so I removed the cover and found a piece of spider gear on the bottom of the case. So out it came and this is what I found. Don't think this is how the clutches are to be stacked. Got all new parts and putting back together.

 

[Chief USA]

If that cannot be repaired economically, maybe it's time for an Eaton TruTrac.

 

[jffmaz]

Some reading here: https://www.cumminsforum.com/threads/dana-80-restack-2.350031/
and attached

 

[JMcCoy]

Hopefully you can just replace the spider gear and restock the clutches. Who knows what else they worked on so I would drag my eye across the wear pattern on your ring & pinion while you're in there. Good luck.

 

[2Farr]

Apparently this is how it was built up at the factory. With 215K on it guess it lasted ok. Dana has a kit for this repair, clutches and cross with new spiders for $330.00 Replacing the bearings while I am in there. Other than that everything else looks good.

 

[BigPapa]

Did you buy this truck new?

 

[2Farr]

Purchased it used. I figure I paid $1.00 per pound for it. Body was in very good shape. Drive train was so, so.

 

[RBeard]

Just installed new clutch-pak in my D-80, comes with new spider gears and cross. Piece of cake unless you change the bearings. And the clutch plates come with a ty-rap holding them in the right order. $320.00 delivered

 

[BigPapa]

Apparently this is how it was built up at the factory.

Purchased it used.

I would imagine someone did that before you got it. Probably either someone trying to tighten the clutch up or trying to loosen it up. I do not believe it left Dana/Spicer like that.

 

[2Farr]

The Dodge manual shows how they want the stack up. Its not how I'm going to do it.