TK4778 Premium Dana 80 Rear Diff Overhaul Kit for 2000-2002 Dodge Ram

TK4778 Torque King® 2000-2002 Dodge Dana 80 Premium Differential Bearing and Seal Overhaul Kit with Shims features Timken® Bearings and genuine original equipment Dana Spicer Small Parts. TK4778 includes Differential and Pinion Bearings, Inner/Outer Pinion Seals, Pinion Nut, Pinion Washer, Outer Pinion Slinger, Pinion Depth Shims, Differential Shims, Pinion Preload Shims, 2 Axle Shaft Flange Gaskets, Threadlocker, Gear Marking Compound, and RTV Sealant. Mostly USA Made, some parts may be imported.

Also see QU50437 Standard Diff Bearing and Seal Kit for Dodge Dana 80 Rear Axle

Need More Info? Use the handy Links below to access over 40 years of Dan's product and vehicle specific Tech Notes to easily get the information you need for your vehicle's repair, maintenance, or upgrade project!

Dan the Gear Man® Tech Notes:
Recommended Re-bearing Time
Kit Components
Matching Kit Parts
Service Procedures
Shims
Other Matching Parts
Applications

Tech Note 1: Recommended Re-bearing Time
Gear set breakage caused by worn and loose Differential Bearings is one of the biggest killers of rear axles. When the differential bearings wear, the backlash between the ring gear and pinion gear will change. Most often, it increases as the ring gear side differential bearing usually takes the brunt of the wear. As the backlash increases beyond approximately 0.010", the chances of breaking a gear tooth increase dramatically. Additionally, a rough and worn differential bearing is very likely to break free and spin on the differential case which will usually mean the case must be replaced. To minimize the chances of wrecking expensive differential parts, I recommend completely re-bearing Dana 80 axles at or before 150,000 miles.

Tech Note 2: Kit Components
2 Each QU50402 Timken® Differential Bearing Cup and QU50403 Timken® Differential Bearing
1 Each QU50404 Timken® Outer Pinion Bearing Cup and QU50405 Timken® Outer Pinion Bearing
1 Each QU50409 Timken® Inner Pinion Bearing Cup and QU50410 Timken® Inner Pinion Bearing
QU40261 Dana 80 Differential and Pinion Shim Kit with QU40061 Pinion Nut and QU40250 Pinion Washer
QU40335 1st Design Pinion Seal
QU40248 2nd Design Pinion Seal
QU40251 Pinion V-Seal (Outer Wiper Seal)
QU40095 Outer Pinion Slinger
2 QU40078 Axle Shaft Flange Gaskets
S82194 RTV Sealant
S24200 Threadlocker
QU90008 Gear Marking Compound
QT9404 Brush

Tech Note 3: Matching Kit Parts
Matching Parts for TK4778 Dana 80 Rebuild Kit are:
QU40096 Ring Gear Bolts
QU40343 Differential Cap Retaining Bolts
QU40306 Axle Shaft Flange Bolts
QU40260 Outboard Differential Bearing Spacers
QU40218 Limited Slip Lubricant
QU40709 U-Joint to Pinion Yoke Strap and Bolt Kit
QU10636 Pinion Yoke
QU40118 Stock Locking Spindle Nut (NEVER reuse stock type spindle nuts)
QU40115 Spindle Nut Lock Wedge (NEVER reuse spindle nut lock wedges)
TK8356 Wheel Bearing Kits for Single Rear Wheels
TK8324 Wheel Bearing Kit for Dual Rear Wheels
QT1032 Differential Case Spreader
QT1004 Inner Pinion Bearing Installer

Tech Note 4: Service Procedures
Do the job right the first time. See my 26 page, color illustrated TM4400 Pinion and Differential Bearing Service On Dana-Spicer Monobeam Axles with over 75 photos for the correct differential bearing replacement and adjustment service procedures.

Tech Note 5: Shims
If you are changing gear sets, your new Pinion Depth must be set before calculating the differential shim pack thicknesses. After setting the pinion depth, use a dial indicator and QT1099 Master Bearings to determine the amount of shims required to get the required gear lash and differential bearing preload.

Tech Note 6: Other Matching Parts for 2000-2002 Dodge Dana 80 Rear Axles
QU50402 Timken Differential Bearing Cup
TK4889 Premium Differential Bearing Kit only 1994-2002
QU50403 Timken Taper Bearing
QU50437 Standard Differential Bearing and Seal Kit
QU40213 Dana 80 Differential Shim Kit
QU40260 Outboard Differential Bearing Spacer Set
QU40078 Axle Shaft Flange Gasket, most Dodge
QU40491 Bare Differential Case for 3.54 Ratio
QU40490 Bare Differential Case for 4.10 Ratio
QU42031 Reuseable Differential Cover Gasket
TM4400 Pinion and Differential Bearing Service Manual for Dana Monobeam Axles
QU90008 Gear Marking Compound
QT1032 Differential Case Spreader
Exploded View XV2011 2000-2002 Dodge Ram 2500, Ram 3500 Dana 80 Rear Axle

Applications:
Dodge:
Dodge Ram 2500 with V-10 or Diesel Engine and a Manual Transmission: 2000, 2001, 2002
Dodge Ram 3500 with all engine and transmission combinations: 2000, 2001, 2002