Update! So here is what happened to us...
So we ending up buying a Bench Tested KNS 80 replacement. I felt like this was the answer. We took out the old one, and put in the new one.. it was hard to get back in... but it did go in. And it didn't go all the way flush... but it was tight and secure. I went flying.... I was getting a DME reading that was CORRECT, but not calculations of KT or MINs. And our VOR Indicator had a flag. So I landed and the next day I tried again. I reseated the KNS 80 again, it was in all the way it would go. The next test flight, better, but still not right. Now we had no Flag indication, and the VOR was receiving. We had a good DME but again no KT or Mins.. and the VOR indicator did not show a TO /FROM indication at all. The needles just swung back and forth. We were disappointed! We had an Avionics Mech.. look at it too. The only thing he could figure is that the unit was not going all the way in... but why? We are not sure. Bottom line, we have to send back the KNS 80 to the seller. :-( When we put back our old unit.. OH it fit so nicely in and I could FEEL it engage. We got our VOR indication back and all was back the way we started. We have VOR tracking but no DME indicators.....
If you think you know why this happened let me know. Also if you ever have a KNS-80 you know works and you are willing to let us try it, please let us know. For now we decided to keep our old one and use the Reliable VOR only signal (as a back up of course) We do have a Cert. Garmin 430 for primarily nav.
Thanks for reading and listening!
Dana