Author Topic: Dana 80 swap - westcoast style  (Read 13112 times)

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Offline u2slow

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Dana 80 swap - westcoast style
« on: July 2, 2014, 01:16:32 am »
i had some time today... and one thing led to another.

I yarded out the tired Dana 70u on sacked-out leafs. The narrow-ish track is due to the 3rd-gen wheels on SRW axle.

DD: 90 D250 6BT|5spd|D60/3.54/Lockright
Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

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    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #1 on: July 2, 2014, 01:19:55 am »
    Here is the Dana 80 SRW axle I hacked out of a scrap frame.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #2 on: July 2, 2014, 01:29:38 am »
    This is as far as I got with the hangers today.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #3 on: July 2, 2014, 01:32:00 am »
    Few pics after I wrapped up tonight....
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #4 on: July 5, 2014, 07:48:43 am »
    Worked on the hangers some more yesterday.... welded them up to my liking. Got them in for a trial fit. Got the 33" tires in there, and the truck is resting on the ground to see how its going to sit.  8)  Right now its 2" taller than the front. 
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Money shot!
    « Reply #5 on: July 7, 2014, 04:12:07 am »
     ;D

    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline Big Isle Boy

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    Re: Dana 80 swap - westcoast style
    « Reply #6 on: July 7, 2014, 02:19:45 pm »
    Nice! Lot's o work there!
    1990 RC LE   360/auto    
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    70 Chrysler 300 Convertible   440/auto   power everything
    Quote from: fal308
    Get rid of those blocks

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #7 on: July 8, 2014, 02:10:55 am »
    Nice! Lot's o work there!

    Thanks!

    Any commentary on the pinion angle?
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #8 on: July 11, 2014, 04:13:11 am »
    Think I got it.... one side mocked up.  ;D The other hanger is cracked and needs mending.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #9 on: July 12, 2014, 03:59:13 am »
    and done  8)
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #10 on: July 13, 2014, 03:23:25 am »
    Takin' a break tonight.... been doing all this after work starting July 1st. Kind of exhausted  :P

    Here's what I accomplished in one shot:
    - Dana 80 upgrade (11.25" vs 10.5")
    - spline upgrade (35 vs. 32)
    - wider axle (70" vs 65")
    - 9/16" wheel studs
    - no driveshaft mods
    - larger brakes (that work) and slide-off drums (13" vs 12")
    - 4" lift
    - longer leafs (60" vs. 56")
    - shackle flip (supposedly better ride)
    - same ratio (3.54)
    - open diff is ready for a lockright (gonna steal from D250)

    Still have to put the cover on, fill with lube, hookup brakes, install shocks, and take for a test drive. Needs to be ready for camping trip July 21.  :o
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #11 on: July 15, 2014, 08:29:18 am »
    test drove no shocks or brakes seems okay  ;D
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline mttaff

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    Re: Dana 80 swap - westcoast style
    « Reply #12 on: July 15, 2014, 09:00:48 am »
    You've been busy! good work. eric
    78-90 crewcab:    D60's, Cummins swap,  6" lift on 37's.

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #13 on: July 18, 2014, 12:28:32 am »
    Finished up shocks and brakes  8) 

    I mounted the brake line block on the lift block. It was the only spot that all the lines would reach to.

    I cut the shock studs off the old ubolt plates and welded them to the 2nd-gen plates. Not pretty... but does the job for now.

    It rides really GREAT too ;D The old suspension rode like a brick. Its even the same shocks on there.  :D
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #14 on: July 19, 2014, 04:36:28 am »
    ok... final pic with 2" front spacers, 3rdgen wheels, 295/70R17 Toyos, & camper  8)

    Rear rides superb... like cadillac with camper  ;D

    Front is very 'firm' still. I repaired the ovaled holes in the hanger. I have a winch bumper to steal off the D300... any extra weight should help too.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #15 on: July 28, 2014, 07:34:40 pm »
    Got back from camping in one piece  8)  I put 1000km on it (600+ miles?) including some mountain grades. Hubs ran cool. Brakes worked great.  Pinion seal leaked a bit, but it was still overfilled when I checked before the ride home. Kiddos insisted on posing with the truck  ;D

    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #16 on: December 19, 2014, 10:24:18 pm »
    It was time to address the pinion & hub seals. Put in the Lockright while I was at it, and straightened up the shocks. Stock 95 shocks oddly enough  ;D
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #17 on: January 31, 2017, 02:44:21 am »
    I totally missed the parking brakes.

    What I did was hook the 2ndgen diff's cables to the 1stgen main cable. Strung them out tight, and that decided the bracket's location. There's actually lots of wheel cable this way... nice for a lifted truck.

    I chose random scraps of stuff for cable guides. You're also seeing my #2/0 battery cable dressed similarly. ;D
    « Last Edit: January 31, 2017, 02:47:18 am by u2slow »
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline Chette10

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    Re: Dana 80 swap - westcoast style
    « Reply #18 on: March 26, 2017, 02:36:59 pm »
    so i have a question, You put 2nd gen hangers and leaf springs in the rear suspension? just lowered them to where you wanted them for the 4in lift? welded a piece of angle iron on the bottom and mounted them to the frame?

    How has it held up the last 3 years if thats what you did?
    I have a 1993 Dodge Ram W250 Clubcab and my rear of front hanger is rusted out. I cant find any front of rear hangers any where online. i have successfully found some rear of rear hangers but no luck for the fronts. On this same website i found 2nd gen hangers for the rear front&rear. So im wondering should i just order the 2nd gen hangers and use them on my 1st gen. your thoughts?
    1993 Dodge Ram W250. Just gettin started on it.

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #19 on: March 26, 2017, 04:40:26 pm »
    It's holding up great. I got the idea from Ford... their hangers sit lower. Also, there's a ford shackle that's about twice as beefy.

    It might be getting time to upgrade the leafs though. They're just stock/used '95 2500 leafs, and they've taken a beating from how I use the truck.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline Chette10

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    Re: Dana 80 swap - westcoast style
    « Reply #20 on: March 26, 2017, 04:55:32 pm »
    Ok so you used Ford's shackles or just got the idea from them?
    I plan on getting my leafs from stengel bros inc because they have a heavy duty 4000lb rated rear leaf spring.
    Thing is I cant buy any yet due to the fact I cant find any rear of front hangers for my 1st gen. I am guessing that im going to have to get my local metal shop to fabricate me some. depending on price of course.
    1993 Dodge Ram W250. Just gettin started on it.

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #21 on: March 26, 2017, 05:02:22 pm »
    Dodge hangers.... positioning inspired by Ford. ;)

    It's just happens the ford shackle is heavier gauge, and is for a 3" wide leaf.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline Chette10

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    Re: Dana 80 swap - westcoast style
    « Reply #22 on: March 26, 2017, 05:54:01 pm »
    ahhh ok making sense now. still went with the 2nd gen dodge hangers just placement from ford. Thanks for the reply my man, im just trying to get to the bottome of what i should and shouldnt do with my situation !
    1993 Dodge Ram W250. Just gettin started on it.

    Offline CanadianCummins01

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    Re: Dana 80 swap - westcoast style
    « Reply #23 on: December 16, 2017, 07:02:02 pm »
    When you moved the front hanger forward, did you have to drop the fuel tank?

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #24 on: December 17, 2017, 03:18:24 pm »
    I loosened the straps... maybe the front I took off. Wedged the tank over just enough to have access for fasteners.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline CanadianCummins01

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    Re: Dana 80 swap - westcoast style
    « Reply #25 on: December 18, 2017, 08:09:43 pm »
    Ahh right on. Thanks man, Im about to swap in a dana 80 and 63s. How do you like the loc rite? Any tire wear issues?
    I live around rock creek bc and am worried about winter sliding

    Offline stftruck

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    Re: Dana 80 swap - westcoast style
    « Reply #26 on: December 18, 2017, 08:37:31 pm »
    Doesn't Jungle make replacement 1st gen spring hangers?

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #27 on: December 19, 2017, 02:42:53 am »
    For me, a locker is a big part of being able to get around in the winter. Granted, I don't get a lot of snow on the coast, but it is rural. My current Duratracs have been great.

    My truck is manual. Your can really adjust your driving style to not scrub the tires off.

    Jungle doesn't make hangers for 3" wide leafs... that's the main reason I modified these ones.
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline CanadianCummins01

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    Re: Dana 80 swap - westcoast style
    « Reply #28 on: December 21, 2017, 01:41:43 pm »
    I was wondering how much snow you got there, we have almost 2 feet here and it will stay till april. Im running duratracs as well, had them on for 2 years straight and are still in good shape.
    I generally try to stay out of the deep stuff with the dodge, it just doesnt work well.

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #29 on: December 21, 2017, 02:32:19 pm »
    I was wondering how much snow you got there, we have almost 2 feet here and it will stay till april. Im running duratracs as well, had them on for 2 years straight and are still in good shape.
    I generally try to stay out of the deep stuff with the dodge, it just doesnt work well.

    Yeah... no snow like that. 2009 was the last year we had anything close to a foot. Two years ago no snow at all. When we get it, its basically gone again in a week. The real problem is the limited snow clearing resources on a small island, and putting up with the mess while it melts. With the locker, I don't have to worry about the roads being cleared/salted for a 4:30am commute.

    We've done more snow in the Jeep actually. (Liberty with Nokians) We regularly drive the Coquihalla + connector in winter, locked front in 4Hi. Of course, the plows are on that steady, so its never very deep. Also did Fort Nelson a few years back in winter. Hundreds of highway km's in 4Hi locked. Yeah, I kind of laugh/shrug when people say winter and lockers don't mix.  ;D
    « Last Edit: December 21, 2017, 02:39:51 pm by u2slow »
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline CanadianCummins01

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    Re: Dana 80 swap - westcoast style
    « Reply #30 on: December 23, 2017, 05:43:57 pm »
    You might not get much but I bet it is all wet, heavy sludge. Ours is mostly powder. I will deffinatly keep thinking of that locker.

    If the front is locked it would different than in the rear. My wife just sold her liberty...I cant say I will miss it. Chased evap leaks for too long.

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #31 on: March 29, 2018, 11:35:04 pm »
    Here's a 5000# load of roofing on the shackle-flipped 2ndgen 2500 suspension. (w/ add-a-leaf) No bumpstops. Brakes and scoot felt good.  8) Rear leafs need help.  :-\ I have some custom "2-ton" leafs for a 3500 to go in next.

    BTW, front leafs are the old-school 2-leaf parabolics from Carrier (customsuspension.com).

    Thankfully the truck returned to level again after after unloading it all by hand.  8)
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline Carter124

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    Re: Dana 80 swap - westcoast style
    « Reply #32 on: June 6, 2018, 02:43:41 pm »
     How much wider is the 80 in comparison to the 60 front? I had my 70 let go last weekend and I'd love to ditch the inboard drums if possible

    Offline u2slow

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    Re: Dana 80 swap - westcoast style
    « Reply #33 on: June 6, 2018, 06:46:04 pm »
    About 3".
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

    Offline u2slow

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    • Bilge rat
    Re: Dana 80 swap - westcoast style
    « Reply #34 on: April 7, 2019, 01:16:52 pm »

    How has it held up the last 3 years if thats what you did?

    And still holding up strong! ...hauled 2-tons of road base home the other day (yes, 1 load)
    DD: 90 D250 6BT|5spd|D60/3.54/Lockright
    Tow/haul: 93 W250 Club 6BTA|5spd|D60/80/3.54/Lockright|4" lift|35's|HX35|5x.012s|4" pipe
    Projects: '84 D250 Ramcharger (cummins); '90 W250 Ramcharger (360TBI)
    Hers: 2005 Jeep Liberty V6|6spd|3.73/Trac-lok |3" lift, 245/75R16E Nokians

     

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