Axle Assembly -Dana Model 80, Full-Float
Axle Assembly -Dana Model 80, Full-FloatRemoval
1. NOTE: Axle shafts, rear hubs, rear wheel bearings and the inner wheel bearing oil seals can be installed new, lubricated or adjusted without removing the differential from the rear axle housing or the rear axle assembly from the vehicle.
Loosen the wheel nuts.
2. Disconnect the battery ground cable(s).
3. Raise and support the vehicle.
4. Disconnect the Anti-Lock Brake Sensor (RABS) at the top of the rear axle housing. Disconnect the RABS harness from the retainers and position it aside.
5. Remove the rear driveshaft.
6. NOTE: Position a suitable drain pan under the axle, below the brake hose.
Unclip the rubber brake hose-to-axle from the rubber brake hose-to-frame.
7. CAUTION: Do not disconnect the linkage assembly, to avoid changing the preset indexing of the valve. If the valve indexing is changed, the entire valve must be installed new.
Disconnect the load-sensing proportioning valve from the differential housing cover. Position it out of the way.
8. Disconnect the rubber brake hose at the load-sensing proportioning valve.
^ Plug the hose and line fittings.
^ Discard the brass washers.
9. WARNING: Be careful that the clamps do not drop from the bar and cause injury.
Remove the rear stabilizer bar.
10. Remove the shock absorber lower nuts. Do not remove the retaining bolts at this time.
11. Remove the supports and lower the hoist completely.
12. Remove the shock absorber lower bolts. Position the shock absorbers out of the way.
13. CAUTION: The tires must remain on the ground to support the rear axle.
Raise the hoist enough to access the axle U-bolt nuts through the wheel housing.
14. CAUTION: Prevent the front of the rear axle housing from dropping and the brake lines from twisting when loosening the axle U-bolts.
Support the front of the rear axle housing.
15. Remove the axle U-bolts.
16. While watching for obstructions, raise the hoist until the vehicle is clear of the axle and tires.
17. Roll the rear axle from under the vehicle.
Installation
1. WARNING: An assistant must help to position the rear axle due to its weight. Failure to follow this instruction can result in personal injury.
With the vehicle raised to the appropriate height to clear the rear axle and tires, and with the front of the rear axle housing supported, roll the rear axle under the vehicle and position it for installation.
2. While watching for obstructions, lower the hoist until the spring positioning pins contact the axle housing pad. While adjusting the hoist as required, have an assistant align the spring positioning pins to the axle pads.
3. Install the axle U-bolts and snug the axle U-bolt nuts.
4. Alternately tighten the axle U-bolt nuts.
5. Raise and support the vehicle.
6. Position the rear stabilizer bar to the rear axle. Install the stabilizer bar clamp bolts.
7. Attach the load-sensing proportioning valve to the differential housing cover. Tighten the nuts.
8. Connect the RABS harness connector.
9. NOTE: Install new brass washers.
Connect the rubber brake hose, with new brass washers, to the load-sensing proportioning valve.
10. Connect the brake hose to the retainer.
11. Support the rear axle. Install the shock absorber to the brackets at the rear axle.
12. Install the rear driveshaft.
13. Remove the supports and lower the vehicle.
14. Install the wheel nuts.
15. Reconnect the battery ground cable(s).
16. Bleed the hydraulic brake system.