Yukon Gear 1541H Replacement Rear Axle For Dana 80 / 37 Spline / 40in

A Dana 80 rear shaft rarely fails on its own, but heavy towing, a hauling load on a dually, or a motorhome that spends its life near gross weight can twist splines or crack a flange. Yukon YA D47852-1 is a 1541H alloy replacement rear axle for the Dana 80: 37 spline, 40 inches long, with an 8 x 5.22 inch flange bolt pattern. It is listed for Ford F-350 and F-450 dually cab and chassis trucks and the F-53 motorhome chassis.

What the axle shaft does in a Dana 80

The Dana 80 is a full-floating rear axle. The truck's weight rides on hub bearings that sit on a spindle at the end of the axle tube, not on the shaft. The shaft's only job is to carry torque from the side gear in the carrier out to the hub flange, where it bolts on. That is why a full-float shaft can usually be pulled by removing the flange bolts, without taking the hub or bearings apart, and why a truck with a broken full-float shaft can often still roll without the wheel falling off.

1541H is a heat-treatable alloy that Yukon uses for stronger-than-stock replacement shafts. On a working truck the benefit is margin: more resistance to twisting the splines under a heavy pull.

Symptoms of a failing Dana 80 shaft

• Gear oil leaking from the axle flange, which can mean loose flange bolts or a failed flange gasket rather than a hub seal.
• A clunk on take-off that comes from one rear wheel, often twisted splines or loose flange hardware.
• No drive from one side with an open differential, the classic sign of a broken shaft.
• Elongated flange bolt holes or broken studs after the flange was run loose.
• Metal in the differential oil, which also points to carrier or bearing damage worth checking.

How to confirm before buying

Pull the flange bolts and slide the shaft out. Look along the splines for a twist (the splines spiral instead of running straight), check the flange face for cracks, and roll the shaft on a flat surface to check for a bend. Our Dana 80 rear axle problems and rebuild cost guide walks through the carrier, pinion and hub faults that cause similar noises, and transmission vs differential noise helps rule out the driveline ahead of the axle.

Fitment

Yukon lists this shaft for 1994-1997 Ford F-350 dual rear wheel cab and chassis, 1999-2008 Ford F-450 Super Duty dual rear wheel cab and chassis, and 1999-2004 and 2006-2008 Ford F-53 motorhome chassis, all with the Dana 80 rear. Dana 80 shafts are not all the same. Spline count (35 or 37), length and the flange bolt pattern all vary, and Yukon even lists both 35 and 37 spline Dana 80s for the 1994-1997 F-350. A 35-spline 38.74 inch shaft with an 8 x 4.02 inch pattern is a different part, like our 35-spline Dana 80 left-hand axle. Count your splines, measure the old shaft and the flange bolt circle, or send us your year and VIN. More driveline parts are in our hard parts category.

Install notes

• Support the truck, remove the flange bolts, and pull the old shaft straight out. Catch the gear oil that follows it.
• Clean the hub and flange mating faces and use a new flange gasket. Torque the flange bolts in a cross pattern to the value in your service manual; loose flange bolts are a common cause of shaft damage.
• With the shaft out, look into the carrier. If the side gear splines are damaged or the oil is full of metal, plan carrier work. A Dana 80 carrier bearing kit or a Dana 80 master overhaul kit covers the bearings and seals; that overhaul kit is for 1998-up Fords with the 4.375 inch OD pinion bearing race, so check yours first.
• Refill with the gear oil weight on your axle tag or in your owner's manual, and recheck the level after a short drive so the hubs fill.

In stock and shipping the same business day from the USA.

Will this fit my Ford F-350 dually?

Yukon lists it for 1994-1997 F-350 dual rear wheel cab and chassis trucks with the Dana 80 rear. Yukon shows both 35 and 37 spline Dana 80s for those years, so count your splines before ordering.

Does it fit an F-450 or F-53 motorhome chassis?

Yes, Yukon lists 1999-2008 F-450 Super Duty dually cab and chassis and 1999-2004 and 2006-2008 F-53 motorhome chassis with the Dana 80 rear.

Do I need to remove the hub bearings to change it?

Normally no. The Dana 80 is full-floating, so the shaft bolts to the hub flange and slides out once the flange bolts are removed. The hub and bearings stay on the spindle.

How do I know I have the right shaft?

This one is 37 spline, 40 inches long, with an 8 x 5.22 inch flange bolt pattern. Match all three on your old shaft, or send us your year and VIN.

Is one shaft for both sides?

Yukon lists this as a Dana 80 rear axle in a single length. Measure both of your old shafts; if they differ in length, confirm with us before ordering a pair.