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Discussion Starter #1
I have a 99 ford F-350 with a dana 80 rear differential. It started gradually getting noisy so I took it apart to find the inner pinion and race are shot. I removed them and pressed a new bearing on and drove in a new race. While in there I went ahead and replaced the outer pinion bearing and race.This is where the problem occurs. I put a new seal in and before I even get the nut snug the yoke is rubbing the seal. I take it all back apart to check the bearings and races to make sure they are the correct ones and correct thickness, and they are. I also checked the seal and found it was also identical to the old one. When I originally took it apart it had two shims on the inner pinion and one on the outer between the yoke and outer bearing. I eventially got a bunch of ford nine inch shims and had to shim the yoke about 3/8 inch so it wouldnt rub the seal. The downfall is now the pinion nut is flush with the threads and i am afraid it may back off. It lasted about three days and now the pinion is leaking. I drove the races flush in the housing does anyone know if this is the wrong thing to do? That is the only thing I can see that may cause it to need shimming. Open for suggestions?
 

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something doesn't sound right. Are you sure you got the outer pinion bearing race all the way back in?
 

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Discussion Starter #3
dana 80 problem

I am not 100% sure but I am pretty sure. I think that if it was not all the way back the yoke would rub even more. It almost acts like it is too far back setting the bearing deeper requiring more shims to get the yoke away from the seal. Here is my setup maybe I lost something during disassembly. I have the pinion with two thin shims next to the gear then the bearing pressed on. next two small shims slid on the shaft on the front side of the same pinion bearing. next the outer pinion brearing. then one larger shim, the yoke, washer, and nut. Am i missing anything? I noticed these dont use a crush sleeve, this seems strange.
 

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Hmm.. I'm not 100 percent sure but I think there should be a "crush" sleeve in between the pinion and yoke. I can't remember if the Dana 80 uses one but I would think it does.

Maybe not

http://www2.dana.com/pdf/AXSM-0053.PDF

check that out. on page 1-4 there is an exploded view of the axle. You can use that to see if you replaced all the right components.
 

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What ended up happening with this. Did you for get the #8 thrust washer? JJ
 
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