Revolution Gear & Axle 05-21 Ford F-250 Super Duty/F-350 Super Duty Dana 60 Drive Flange Kit

If your 2005-2021 F-250 or F-350 Super Duty drops out of four-wheel drive, will only pull in LOCK, or has a hub that slips and grinds when you load it with big tires, the Revolution Gear and Axle D60S-FLANGE-KIT takes the hub lock out of the equation. It swaps the factory hub locks for solid drive flanges, often called drive slugs, so the front axle shafts are tied to the wheel hubs full time.

What drive flanges do on a Super Duty Dana 60

From 2005 on, the Super Duty front Dana 60 and Super 60 use a locking hub on each wheel that connects the outer stub shaft to the unit-bearing hub. In AUTO the hub depends on engine vacuum reaching it through lines and seals in the steering knuckle. In LOCK it relies on internal teeth that can wear or break under heavy tires and hard launches. A drive flange replaces that whole assembly with a one-piece splined slug that slides over the 35-spline stub shaft and bolts to the hub face. Nothing can slip and nothing depends on vacuum. The trade is that the axle shafts, front differential gears and front driveshaft now turn whenever the truck rolls, even in two-wheel drive. Shifting the transfer case still decides when the front axle is powered.

Symptoms that point to the hub locks

• 4x4 works with the dials in LOCK but not in AUTO
• One front tire pulls and the other does nothing on a slick ramp
• Grinding, ratcheting or clicking from one hub under throttle in 4x4
• A hub that pops out of engagement when the steering is turned hard
• Hubs that failed again after vacuum lines and seals were replaced

How to confirm it before you buy

Turn both dials to LOCK, select 4x4 and see if both front tires drive. If LOCK works but AUTO does not, you have a vacuum leak, and our Super Duty vacuum hub lock guide shows how to find it with a hand pump. You may only need a 2005-2010 hub lock vacuum line. If a hub slips even in LOCK, or you are done chasing leaks, drive flanges are the permanent fix. While the front end is apart, check the ball joints and unit bearings too; the Dana 60 front axle problems guide covers both.

Fitment

This listing covers the 2005 through 2021 Ford F-250 Super Duty and F-350 Super Duty with the front Dana 60 or Super 60. Revolution lists the kit for 2005-and-newer Ford Dana 60 and Super 60 front axles with stock or aftermarket 35-spline outer stub shafts. Spline count decides it: if your truck has aftermarket 40-spline stubs, this kit will not fit. It also does not fit the 1985-1998 F-250 and F-350 Dana 60, which takes the 1985-1998 Revolution D60 flange kit with a different hub pattern. If you are not sure what is on your truck, send us your year and VIN.

Install notes

• Each kit has two drive slugs, two aluminum caps, O-rings, spacer rings and twelve stainless socket head cap screws.
• Raise and support the front, then remove the factory hub lock from each hub. Clean the hub face and the stub shaft splines.
• Fit the spacer and O-ring, slide the slug onto the stub splines, and bolt it to the hub. Torque the screws evenly to the value your service information or the kit sheet gives. Install the cap.
• With hubs gone, the AUTO vacuum system no longer engages anything on that axle.
• Keep the front axle serviced, since it now turns all the time. Use 75W-90 or 75W-140 gear oil.
• If the truck has big tires and a worn front end, pair this with the Yukon 1999-2019 Super Duty ball joint kit, or regear with a Dana 60 front ring and pinion and an install kit.

Does this fit my 2005-2021 F-250 or F-350 Super Duty?

Yes, if it has the front Dana 60 or Super 60 with 35-spline outer stub shafts, which is the stock setup. Trucks with aftermarket 40-spline stubs need a 40-spline flange kit.

Will my front axle turn all the time with drive flanges?

Yes. The flanges lock the shafts to the hubs permanently, so the axle shafts, front gears and front driveshaft spin whenever you drive. The transfer case still controls when the front axle gets power.

Will this fit an older 1998 or earlier Ford Dana 60?

No. The 1985-1998 F-250 and F-350 Dana 60 uses a different hub pattern and takes the Revolution D60-FLANGE-KIT instead.

What is in the kit?

Two drive slugs, two aluminum caps, O-rings, spacer rings and twelve stainless socket head cap screws, enough for both front wheels.

Should I just fix the vacuum system instead?

If LOCK works and only AUTO fails, a vacuum line or knuckle seal fix keeps your hubs. If a hub slips in LOCK, breaks under big tires, or you are tired of vacuum leaks, drive flanges end the problem for good.