Why We Chose the Dana 80 Rear Axle for Our Overland Truck Build & How We Sourced It
The clear choice
When it came to selecting a rear axle for our expedition truck, we needed something robust, reliable, and easy to maintain. This axle isn’t just about moving us down the road—it has to perform in all conditions with absolute dependability. On top of that, it had to meet a few critical requirements: the right width, a heavy weight rating, and compatibility with aftermarket gears and lockers.
After weighing our options, the choice became clear: we went with a Dana 80 axle.
The Dana 80 checked every box for us. It carries a weight rating of up to 11,000 lbs, is available in the 8x6.5 bolt pattern we wanted, and was produced in multiple widths by all three major truck manufacturers. Gear and locker options are abundant, aftermarket support is strong (including bigger brakes and heavy-duty axle shafts), and it’s a proven favorite in the off-road and overland community for being both strong and reliable.
Narrowing Down the Dana 80 Options
Once we decided on the Dana 80, the next step was finding the right variant. Since we were set on the 8x6.5 bolt pattern, we ruled out any 10-lug models. That still left us with Ford, Chevy, and Dodge axles to consider.
Ford: Most Dana 80s in Ford trucks were 10-lug, and reliable documentation on 8x6.5 versions was scarce. We decided not to waste time chasing an uncertain option.
Chevy: GM primarily used the 14-bolt, and the rare Dana 80s they did produce weren’t well-documented either. In one case, even the truck’s owner wasn’t sure what axle it had and with our help couldn’t identify it. We crossed Chevy off the list.
Dodge: From 1994–2002, Dodge used true Dana 80s in all 3500 models. These came in two widths with two brake configurations: a 72” WMS (wheel mounting surface) for standard 3500s, and a narrower 67.5” WMS for cab chassis models. Since the 72” version was too wide for our setup, the cab chassis axle was the clear choice.
Hunting Down the Right Rear Axle
Our first find was a retired plow truck listed on Marketplace. We bought the axle for $450 and pulled it ourselves. Unfortunately, once we got it home we discovered the drum brake backing plates were completely rotted out—unsurprising given its life as a plow truck, but replacements were nearly impossible to source. We sold that axle and resumed the search.
Next, we tracked down a cab chassis Dana 80 from a junkyard in North Carolina. It had lived under a tow truck and was retired due to a wheel bearing issue. On the Dana 80, the wheel bearing retaining nuts are held in place by a wedge driven into a groove on the axle. Over time, that wedge can loosen and fall out, allowing the nut to back off and the bearing to fail. Typically this destroys the hub and axle, but in this case the owner caught the issue early.
The junkyard delivered the axle to our door for $950. Since we planned on a full rebuild anyway, the bearing issue wasn’t a concern.
Why the Dana 80 Was the Best Choice for Our Overland Truck
This axle is far stronger than we’ll ever realistically need, but that’s exactly the kind of overbuild we wanted for long-term off-road reliability. It’s in solid condition, parts are easy to source, and the Dana 80 has an excellent reputation among off-roaders.
The Dana 80 ended up being the ideal rear axle for our overland truck. It’s stronger than we’ll ever realistically need, well-supported in the aftermarket, and easy to maintain no matter where the road takes us. After narrowing down the options and sourcing the right variant, we finally have a foundation we can trust for the long haul.
With the axle in hand, we’re ready to dive into the rebuild process and modifications that will make it perfectly suited to our rig. Stay tuned—we’ll be sharing the full rebuild details.
