Dana 60 Rear Axle
Problems and Rebuild Cost

The Dana 60 rear is one of the toughest axles ever bolted under a pickup, which is why so many still run on 40-year-old trucks. They rarely break. They wear: pinion bearings lose preload, hub seals weep onto the brakes, Powr-Lok clutches go flat, and plenty were regeared by somebody who eyeballed the pattern. This page covers the rear axle. For the steering axle under a 2500 or 3500, see our Dana 60 front axle guide.

Which Trucks Have a Dana 60 Rear

• Ford F-250 and some F-350s, 1970s to mid-1980s. Semi-float and full-float, until the Sterling 10.25 took over in the mid-1980s.
• Dodge D and W 200/250/350, 1970s through early 1990s. Mostly full float.
• Some GM 3/4-ton trucks. Before the 14-bolt took over. A 14-bolt cover is not a Dana 60; see our GM 14-bolt guide.
• 1994-2002 Ram 2500 (lighter-duty trucks). Semi-float Dana 60; the heavy-duty 2500 got a Dana 70. Read the tag.

No tag? Look for a 10-bolt cover, a ring gear of about 9.75 inches, and usually "60" cast into the housing. A Dana 70 also has 10 cover bolts but is visibly bigger.

Dana 60 vs 61 vs 60HD

The Dana 61 is a Dana 60 with the pinion in a different position, used in some older Ford and Dodge trucks. Bearings and seals are largely shared, hence 60/61 master kits, but gear sets may not swap, so confirm with the tag. 60HD usually refers to the heavier full-float versions on 1-tons, often with 35-spline shafts.

Semi Float vs Full Float, 30 vs 32 vs 35 Spline

On a semi-float Dana 60 the axle shaft carries the truck's weight and the wheel bearing rides directly on the shaft. Break one and the wheel can come off. These are almost always 30 spline. On a full floater the hub rides on two tapered bearings on a spindle and the shaft only drives the wheel.

Full-float shafts come in 30, 32 and 35 spline depending on make, year and rating, with 35 spline common on 1-tons. Pull a shaft and count before ordering. For a twisted 30-spline semi-float shaft, the Yukon 4340 chrome-moly rear axle for the 30-spline Dana 60 ($420.07) is the upgrade. For 35-spline full floaters, see the Yukon 1541H alloy rear axle for the Dana 60, 70 and 80 ($326.70), or the 31-33.5 inch version ($392.70). Measure shaft length first.

Pinion Bearing Whine

A high-mile Dana 60 rear that whines at 45-60 mph almost always has worn pinion bearings or gears worn from low oil. In-and-out clunk at the yoke means loose bearings. A hum that changes when you swerve is more likely a hub bearing. See our whine diagnosis guide.

Most Dana 60 rears set pinion preload with selective shims, not a crush sleeve, so tightening the pinion nut will not take up slop. The USA Standard Dana 60/61 rear master overhaul kit ($199.99) covers the job; the Yukon Dana 60/61 rear master overhaul kit ($484.87) and Timken Dana 60 master bearing kit ($233.99) are the alternatives. If only the carrier bearings are bad, the Dana 60 carrier bearing kit ($112.99) is enough.

Spread the housing a few thousandths with a Dana 60 housing spreader ($145.99). Over-spreading bends it for good. Pull bearings with a Dana 30/60/70 clamshell bearing puller ($170.99). If the yoke has a groove where the seal rides, replace it; the Yukon Dana 60/70 1350 yoke ($204.89) fits many 29-spline pinions. See our pinion seal guide.

Full-Float Hub Seal Leaks

On a full floater, gear oil runs out the tubes to lube the hub bearings. A worn inner hub seal dumps oil onto the brake shoes, and a torn flange gasket leaks out the face of the hub. Check the vent first; a plugged one pushes oil past every seal.

Adjust hub bearings properly: seat them while spinning the hub, back off, snug to the manual's low spec, then lock it. Too tight cooks the bearings; too loose chews the new seal. The 13-piece spindle nut socket set ($158.99) covers the common nuts. Replace oil-soaked shoes.

Powr-Lok Chatter

Many Dana 60 rears came with a clutch-type Powr-Lok. Worn clutches or missing friction modifier make it chatter in tight turns or act open on ice. Try fresh fluid and modifier first. If it still chatters, rebuild it with the Yukon Dana 60 and 70 Powr-Lok clutch set ($189.89). If the case is worn, the Yukon Dura Grip for the 32-spline Dana 60, 4.10 and down ($1,094.17) is a new limited slip. For a hard locker on 35-spline shafts, the Eaton ELocker4 Dana 60, 4.10 and down ($1,488.99) and 4.56 and up ($1,488.99) are the picks. See open vs limited slip vs locker.

Regears and the 4.10 / 4.56 Carrier Break

Factory ratios ran about 3.54 to 4.56. The carrier changes between the 4.10 and down and 4.56 and up ranges. Going from 4.10 to 4.56 or deeper means a new carrier; the Yukon Dana 60 open carrier, 4.10 and down ($379.61) fits the shallow side only. For bigger tires, the Yukon Dana 60 4.56 gear set ($531.10) or 4.88 thick gear set ($532.13) are common. Use standard rotation only; reverse-rotation gears are for high-pinion fronts. See picking a ratio.

Pinion depth is a shim under the inner pinion race; backlash and carrier preload are shims behind the carrier bearings. Backlash usually lands around .005-.010 inch; follow the gear maker's spec. You need a dial indicator with magnetic base ($47.99), an inch-pound torque wrench ($79.99) for preload, and new ring gear bolts. The USA Standard Dana 60 rear pinion install kit ($234.16) covers the pinion side. See our backlash and pinion depth guide.

What It Costs: DIY vs Shop

DIY assumes you own the spreader, puller and a press. A Dana 60 rear holds roughly 3 to 3.5 quarts; fill to the bottom of the fill hole and add friction modifier with a Powr-Lok. The differential fluid change guide covers intervals. For a dented cover, the nodular iron Dana 60 cover ($239.99) or Yukon Hardcore cover ($333.89) is the fix.

Parts and Tools for the Job

More bearing kits are in our rebuild kits section, gear oil and friction modifier in fluids, and pullers and gauges in tools. CoreTransmissionParts.com carries transmission and transfer case parts if the noise is further up the driveline.

FAQ

How do I tell if I have a Dana 60 rear axle?

Look for a 10-bolt cover, a ring gear of about 9.75 inches and a tag on one of the cover bolts. A Dana 70 also has a 10-bolt cover but is visibly larger, and a GM 14-bolt or Ford Sterling has more cover bolts.

Is my Dana 60 rear 30, 32 or 35 spline?

Most semi-float Dana 60s are 30 spline. Full floaters can be 30, 32 or 35 spline depending on make and year, with 35 spline common on 1-tons. Pull a shaft and count the splines before ordering axles, spider gears or a locker.

Does a Dana 60 front gear set fit a Dana 60 rear?

A standard-rotation Dana 60 gear set fits the rear and most older front axles. Reverse-rotation gears are for high-pinion front axles only and will not work in a rear. Also match the carrier range: 4.10 and down or 4.56 and up.

How much does a Dana 60 rear rebuild cost?

A DIY bearing and seal overhaul runs roughly $200-$500 in parts. A shop overhaul with the existing gears is usually about $900-$1,500. A regear with new ring and pinion and a master kit runs about $1,500-$2,500 at a shop, and adding a locker can push it past $3,500.