Revolution Gear & Axle 00-07 Ford 10.25in/10.5in Rear Axle Ring & Pinion Master Install Kit
If you are putting new gears in the Sterling rear axle of an older F-250, F-350 or Excursion, whether for bigger tires, a heavier trailer or a whining pinion, this is the bearing and hardware kit that goes in with them. The Revolution Gear & Axle 35-2046 is a new master install kit for the Ford 10.25 in. axle and for the 1999-2007 10.5 in. housing when it is fitted with 10.25-pattern aftermarket gears. Read the fitment section closely: this kit is matched to the gear set, not only to the housing.
The Sterling 10.25 and 10.5 are full-floating axles: the hubs carry the truck's weight and the center section carries only the gears and their bearings. The pinion turns on two tapered roller bearings held at preload by a crush sleeve, and a shim under the inner bearing sets pinion depth. The carrier rides on two side bearings, and shims behind them set backlash and carrier preload. All of these bearings must be pressed off and replaced when gears are changed. Revolution lists the 35-2046 with Timken pinion and carrier bearings, pinion and carrier shims, a pinion seal, crush sleeve, ring gear bolts and a cover gasket or silicone. Axle seals and the ring and pinion are not included.
On a full-floater, a dry or loose hub bearing can sound just like a pinion bearing, so jack up each rear wheel and check for play and roughness first. Then drain the oil, look at the magnet and paint the ring gear to read the pattern. Our Ford Sterling 10.25 and 10.5 problems guide covers the common failure points and what a rebuild costs. If the gear teeth are healthy and you are keeping the factory ratio, buy an overhaul kit made for the original gears instead, such as the Yukon 1999-2007 Ford 10.5 overhaul kit or the Ford 10.25 overhaul kit.
Revolution lists this kit for 1993-1999 Ford 10.25 in. housings and 1999-2007 10.5 in. housings when they run Revolution F10.25 ring and pinion sets. The 10.5 axle came with its own gear dimensions, and a 10.5 being rebuilt on its factory gears takes a different kit (Revolution 35-2046A). The listing shows 2000-2007 trucks, the core of that range. On 2008-2010 10.5 housings, 10.25 gears need a spacer, the 10.25-to-10.5 conversion spacer, which is sold separately. The 2011-and-later 10.5 with the 37-spline pinion is a different axle and takes a different kit. To check which gears are in your axle, read the tag on the cover bolt or the numbers on the ring gear, or send us your year, VIN and gear set and we will confirm. A 10.25-pattern set such as the Yukon Ford 10.25 3.73 gear set is the kind of gear this kit is made for. More axle bearing kits are in rebuild kits.
Published setup values for the Ford 10.25 and 10.5 are a 0.025 in. starting pinion shim, 20-35 in-lb of new pinion bearing preload, 0.006-0.010 in. backlash, ring gear bolts at 95 ft-lb and bearing caps at 80 ft-lb. Crush the new sleeve slowly and check preload often, because once the sleeve is over-crushed it has to be replaced. Use new ring gear bolts with thread locker, and paint the teeth to check the drive and coast pattern before final assembly. Our pinion depth and backlash guide explains how to read the marks. While the carrier is out is the time to add traction; the Dura Grip limited slip for the 10.25 and 10.5 drops in with the same bearings. Fill with 75W-90 or 75W-140 gear oil, plus friction modifier for a clutch-type limited slip. Follow the ring and pinion break-in procedure, which means no towing until after the first oil change at about 500 miles.
| Brand | Revolution Gear & Axle |
| Part number | 35-2046 |
| Fits | Revolution Gear & Axle 00-07 Ford 10.25in/10.5in Rear Axle Ring & Pinion Master Install Kit |
| Vehicle fitment | Ford 10.25In/10.5In (2000-2007) |
| Type | Differential Install Kits |
| Condition | New |
| Ships | Same business day (in stock), from the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
No. Revolution makes this kit for 10.25-pattern gears. For a 1999-2007 10.5 on its original gears, use the 10.5 factory-gear kit (Revolution 35-2046A) or a 10.5 overhaul kit. Send us your year and VIN if you are not sure which gears you have.
Only with a spacer. Revolution notes that 2008-2010 10.5 housings need the SK F10.5-Conv spacer to run 10.25 gears with this kit. The 2011-and-later 37-spline 10.5 uses a different kit.
No. This is the bearing and setup kit only. You buy the 10.25-pattern ring and pinion in the ratio you want separately.
Revolution lists Timken pinion and carrier bearings, pinion and carrier shims, a pinion seal, crush sleeve, ring gear bolts and a cover gasket or silicone. Axle seals are not included.
Published Ford 10.25 and 10.5 values are a 0.025 in. starting pinion shim, 20-35 in-lb new pinion bearing preload, 0.006-0.010 in. backlash, 95 ft-lb ring gear bolts and 80 ft-lb bearing caps. Always confirm against the pattern.
