Revolution Gear & Axle 85-98 Ford F-250/F-350 Dana 60 35 Spline Drive Flange Kit

If your 1985-1998 Ford F-250 or F-350 4x4 has a Dana 60 front axle with worn-out locking hubs that grind, slip out of lock or refuse to engage, a set of drive flanges is the simplest permanent fix. This Revolution Gear and Axle D60-FLANGE-KIT replaces both front hubs with solid drive flanges (often called drive slugs) for Dana 60 axles running 35-spline outer stub shafts, so the front wheels are always connected to the axle shafts.

What a drive flange kit does on a Ford Dana 60

On a manual-hub Dana 60, the hub is the only link between the outer stub shaft and the wheel. Turn the dial to lock and a sliding clutch ring couples the splined stub to the hub body; turn it to free and the wheel spins on its bearings while the shaft stays still. A drive flange removes that clutch mechanism. The flange slides onto the 35 splines of the outer stub, bolts to the wheel hub with socket head cap screws, and is held on the stub with a clip ring, then sealed under an aluminum cap. Revolution lists the kit contents as two drive slugs, aluminum caps, retention rings, hub clip rings, O-rings, axle clip rings and eight stainless socket head cap screws. With no moving parts left, there is nothing to wear out, freeze up in the cold or pop out of engagement under load.

The trade-off is that the front axle shafts, U-joints, differential and front driveshaft turn whenever the truck moves, even in two-wheel drive with the transfer case in 2H. Expect a small fuel economy hit and a little more front driveline noise. Many plow trucks, rock crawlers and work trucks accept that in exchange for a front end that is always ready.

Symptoms that point to replacing the hubs

• Hub dial will not turn, or turns but the wheel does not drive in 4WD
• Grinding or clicking from one front corner when 4WD is engaged
• 4WD pops out of lock on a climb or when backing up under load
• Broken internal springs, cracked hub dials or water inside the hub body
• Front driveshaft turns in 4WD but only one front tire, or neither, pulls
• Hubs that keep failing after a bigger tire or locker upgrade

How to confirm the problem is the hub and not the shaft

Jack up the front, lock both hubs, put the transfer case in 4H with the engine off and the transmission in park or in gear, and try to turn each front tire by hand. A healthy corner will not turn. If one tire spins freely, pull that hub cap and look at the stub splines and the clutch ring. If the splines are chewed or the stub moves in and out excessively, the problem is the stub shaft or the axle U-joint, not just the hub, and the flange alone will not fix it. Broken outer stubs are common on built trucks, so inspect them before you order. Our rebuild kits section has the Dana 60 parts for the rest of the job.

Fitment

Our listing covers the 1985-1998 Ford F-250 and F-350 with a Dana 60 front axle and 35-spline outer stub shafts. Revolution describes the kit as fitting 35-spline Dana 60 fronts in Chevy and Dodge trucks and Fords up to 2004, so it also suits many GM and Dodge Dana 60 builds that run 35-spline outers. It does not fit the 2005 and newer Super Duty Dana 60 or Super 60, which take Revolution's separate D60S kit with a different hub pattern. Spline count matters most: count the splines on your outer stub or check its part number before ordering, because many trucks use 30-spline outer stubs and need the 30-spline flange kit instead. If you are unsure, send us the year and VIN.

Install notes

• Remove the old hub caps and hub bodies, clean the hub face and the stub splines, and check the wheel bearings while the hub is open.
• Install the O-ring, slide the flange onto the stub and fit the axle clip ring in its groove before bolting the flange to the hub.
• Tighten the socket head cap screws evenly in a cross pattern using a thread locker, then install the cap with its O-ring so water stays out.
• Check for stub end play after install. If the shaft moves noticeably in and out, fix the spacing before driving.
• Because the axle now turns all the time, check the front U-joints and wheel bearings. A Dana 60 front bearing and seal kit is cheap insurance while the hub is apart.
• If you change your mind later, the Yukon Hardcore 35-spline locking hub set bolts back in the same place.

Fill the front differential with 75W-90 or 75W-140 gear oil to the bottom of the fill hole if the axle is opened. For a full look at common Dana 60 front problems, read our Dana 60 front axle problems guide.

Will this drive flange kit fit my 2006 F-250 Super Duty?

No. 2005 and newer Super Duty Dana 60 and Super 60 fronts use a different hub, and Revolution makes a separate D60S kit for them. This kit is for the older 35-spline Dana 60 front, listed for 1985-1998 F-250 and F-350.

Does my front driveshaft turn all the time with drive flanges?

Yes. The flanges lock the wheels to the axle shafts permanently, so the shafts, differential and front driveshaft spin whenever the truck moves, even in 2H. The transfer case still decides whether the front axle is driven.

How do I know if I have 30 or 35 spline outer stubs?

Pull a hub cap and count the splines on the end of the stub shaft, or look up the stub part number. This kit is for 35 splines only. If you count 30, order the 30-spline flange kit.

What comes in the kit?

Two drive flanges, aluminum caps, retention rings, hub clip rings, O-rings, axle clip rings and eight stainless socket head cap screws, per Revolution Gear and Axle.

Should I replace anything else while the hubs are off?

Inspect the wheel bearings, seals, outer stubs and axle U-joints. Since everything now turns full time, worn bearings or a dry U-joint will show up quickly. Replace them now if they are rough or loose.