I put a used d80 in my cummins a month or so ago and I just filled the fluid everything turned ok so I said whatever well pulling a trailer back 300 miles yesterday I lost the abs speed sensor no mph abs brake light on blah sp I go get another sensor thinking that was shot  pulled it out and half of it was missing well long story short everything meshes and is quiet so I'm going to run it just weird 

That's just it where do you stop, by the time you add it all up and your time maybe a guy is better off find the newer style axle, ora set of them to match.

I can tell you mine ended up costing around $1000 for parts and $100 to cheat and have a shop to replace the parts in carrier for me. I set the pinion and pattern. So $1100 for me to do just about everything myself.  Pain in the ***.  Meanwhile, I saw a D80 for sale in Nebraska for $450.  If it wasn't an open diff I probably would've gone that route.

There seem to be more junk out there and not enough people with brains to work on things anymore.  I really think with good luck and having money and being in right place, you can keep these trucks running for a long time with spear parts.

I took mine to a local off roading shop for rebuild 1000 with a 2 year warranty

1 hour ago, Silverdodge said:

I took mine to a local off roading shop for rebuild 1000 with a 2 year warranty

 

Good call, the off road shops will be experienced in Dana axle repair. They are all the same design, from the small 30's in Jeeps to the 80's in our trucks. The Dana axles are the most difficult/complicated to repair of all axles. The GM 14 bolt and Ford 9" are the easiest, in my opinion.

11 hours ago, NIsaacs said:

 

Good call, the off road shops will be experienced in Dana axle repair. They are all the same design, from the small 30's in Jeeps to the 80's in our trucks. The Dana axles are the most difficult/complicated to repair of all axles. The GM 14 bolt and Ford 9" are the easiest, in my opinion.

That's what I figured

Pics of pinion had to be removed with a fire wrench

Well they were in there the carrier had abnormal wear from heat I guess they said some one set the gears up previously and ya well she's getting a true trac and fully done pumpkin wise but ya ugh never easy blah I will have truck tomorrow