How hard to install new ring gear and pinion on Dana 80? - Dodge Cummins Diesel Forum
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Old 08-22-2009, 01:12 PM   #1 (permalink)
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How hard to install new ring gear and pinion on Dana 80?

How hard is it to install a new ring gear and pinion on a dana 80? time frame? Id like to do it myself if it isnt a pain to replace.
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Old 08-22-2009, 01:30 PM   #2 (permalink)
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its not real hard the hardest thing is to set the tooth pattern and shim it. other wise its not to bad of a job how many miles are on the real end?? your suppose to use an axle spreader but i never did when i replaced mine its kinda hard to get out but it comes out with a little pulling. setting your pinion tension on the bearings is a bit tough to just got to shim it correctly again also. and you while your in their that far apart you should do a new bearing and race kit. than you will have a whole new rear end.
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Old 08-22-2009, 02:12 PM   #3 (permalink)
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How hard is it to install a new ring gear and pinion on a dana 80? time frame? Id like to do it myself if it isnt a pain to replace.
Basically if you have to ask, then you shouldnt set yours up yourself. Gears are very tricky, and its not just a bolt in and go type of thing. First you need to get it all apart which is difficult without some tools.. Then installing new bearings requires a press. Then when reinstalling youll need a way to measure backlash after and during setting pinion depth. Then spin it to check the pattern and tear it all back apart to move shims around to add or remove backlash or pull the pinion out and shim to add depth or not. Basically, $300 bucks for a gear install is money well spent. Youll spend $450 just on the bearing puller.
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Old 08-22-2009, 02:13 PM   #4 (permalink)
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Basically if you have to ask, then you shouldnt set yours up yourself. Gears are very tricky, and its not just a bolt in and go type of thing. First you need to get it all apart which is difficult without some tools.. Then installing new bearings requires a press. Then when reinstalling youll need a way to measure backlash after and during setting pinion depth. Then spin it to check the pattern and tear it all back apart to move shims around to add or remove backlash or pull the pinion out and shim to add depth or not. Basically, $300 bucks for a gear install is money well spent. Youll spend $450 just on the bearing puller.
Yep. agreed

Not to mention the case spreader that simplifies the process.
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Old 08-22-2009, 09:46 PM   #5 (permalink)
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Do not attempt. This is a difficult job for those with training and tools.
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Old 08-22-2009, 09:52 PM   #6 (permalink)
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setting up gears isnt that difficult, granted parts are alot heavier for a D80 compared to a 30/44/60. its very time consuming for someone that has never done one before. your best bet is to buy to set of carrier bearings and make yourself a set of "set up bearings". if you need to know how google it. the only real "specialty" tools youll need are a splitbearing puller, magnetic base/dial indicator, and micrometer. a case spreader helps out considerable, especially when trying to do this under the truck. (i usually pull the whole axle out) a pinion depth gauge is handy but not necessary. check out pirate4x4 for a great write up on "how-to's" of gear set up. sometimes your time is worth the couple hundred extra to have a shop set it up and the peace of mind.
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