Revolution Gear & Axle 03-10 GM/Dodge 11.5in Rear Axle Ring & Pinion Master Install Kit

If you are pulling the center section out of a 2003-2010 Silverado or Sierra 2500HD/3500, or a 2003-2010 Ram 2500/3500, the job is only as good as the bearings and shims that go back in with the gears. Revolution Gear & Axle kit 35-2024 is the master install kit for the American Axle 11.5 inch rear in those trucks. Buyers usually land here for one of three reasons: new gears after a tire or towing change, a rear end that howls under load, or a pinion seal that has been leaking long enough to cook the bearings.

What a master install kit does in an AAM 11.5

The 11.5 is a full-float axle with a big pinion supported by two tapered roller bearings. A collapsible crush sleeve between those bearings holds pinion preload, and shims under the inner bearing set how deep the pinion sits in the ring gear. The carrier rides on two side bearings, and the shims behind them set carrier preload and ring gear backlash. Change any one of those and the tooth contact pattern moves, which is why a new ring and pinion should never go in on used bearings or an old crush sleeve.

Per Revolution's product page, 35-2024 includes Timken pinion and carrier bearings, a pinion seal, a crush sleeve, carrier and pinion shims, ring gear bolts and cover gasket or silicone. It does not include axle seals, and it does not include the ring and pinion itself.

Symptoms that send an 11.5 to the bench

• A whine that rises with road speed and changes pitch between pulling and coasting, worst with a trailer behind the truck
• A low growl or rumble from the axle at highway speed, typical of worn carrier bearings
• Clunk on take-up from a pinion that has lost preload
• Gear oil on the pinion yoke, driveshaft or frame from a failed pinion seal
• Fine metal on the fill-plug magnet, or chunks in the drained oil

How to confirm before you buy

Do a coast test: hold a steady speed, then lift off without braking. Noise that changes between drive and coast points to gear contact or pinion bearings; a steady drone that follows speed points to carrier bearings or wheel hubs. Our whine on acceleration vs deceleration guide walks through that road test, and the AAM 11.5 problems and rebuild cost guide lists what typically wears out. On stands, rock the pinion yoke up, down, in and out. Any play means preload is gone. If the gear teeth are pitted or chipped, order gears with this kit, such as the 11.5 4.10 ring and pinion or the 11.5 4.56 ring and pinion.

Fitment

Revolution lists 35-2024 for the GM and AAM/Dodge 11.5 inch rear axle, 2003-2010. That covers the heavy-duty GM pickups and the Ram 2500 and 3500 of those years. Revolution sells a separate kit for 2011-2013 trucks and another for 2019 and newer 11.5 axles, so the build year matters. The 11.5 is also easy to confuse with the older GM 14-bolt 10.5 inch, which uses a different kit; our 14-bolt vs AAM 11.5 comparison shows how to tell them apart, and the 10.5 owner wants the 98-04 GM 14-bolt 10.5 master install kit instead. If your truck is a 2001-2002 GM or you are not sure which axle you have, send us your year and VIN and we will check it before it ships. Browse more axle parts in rebuild kits.

Install notes

• Record backlash and paint a few teeth before teardown so you have a reference.
• Revolution's setup chart for the GM 11.5 gives a 0.055 in starting pinion shim, 20-30 in-lb pinion bearing preload on new bearings, 0.006-0.010 in backlash, 175 ft-lb on the ring gear bolts and 200 ft-lb on the bearing caps.
• Use the new crush sleeve and tighten the pinion nut in small steps, checking rotating torque each time. Overshoot the preload and the sleeve has to be replaced.
• Read the pattern with marking compound on both drive and coast sides before the cover goes on.
• Fill with 75W-90 or 75W-140 gear oil as your owner manual specifies. For new gears, follow the break-in: no towing at first and an early oil change, covered in our ring and pinion break-in procedure.
• The kit has no axle seals. With the shafts out, it is the right time to do the hubs with the Yukon 11.5 axle bearing and seal kit; Ram 3500 dually owners should use the Ram dually 11.5 bearing and seal kit.

Does this kit fit a 2011 or 2012 Silverado 2500HD with the 11.5 rear?

Revolution lists 35-2024 for 2003-2010 GM and AAM/Dodge 11.5 axles and sells a separate master install kit for 2011-2013 trucks. Send us the year and VIN if your truck is close to the change and we will confirm before shipping.

Is a ring and pinion included?

No. This is the install kit only: Timken pinion and carrier bearings, crush sleeve, pinion seal, pinion and carrier shims, ring gear bolts and cover gasket or silicone. Order the gear set separately in the ratio you want.

Can I use it to rebuild my 11.5 without changing gears?

Yes. If the teeth are in good shape, a master install kit replaces every bearing, the crush sleeve and the pinion seal so the original gears can be set back up. Record the original backlash and pattern first so you can match it.

Does it include axle seals?

No, axle seals are not included. Replace them, or the full hub bearing and seal set, while the axle shafts are out.

What gear oil should I use after the rebuild?

Use the gear oil your owner manual lists for the axle, typically 75W-90 or 75W-140 on these trucks. After new gears, change the oil early as part of break-in.

What pinion bearing preload does the 11.5 use?

Revolution's setup chart lists 20-30 in-lb on new pinion bearings for the GM 11.5, with 0.006-0.010 in backlash. Measure with an inch-pound torque wrench on the pinion nut before the carrier goes in.