Revolution Gear & Axle 99-16 Ford Super Dana 60 Front Crush Sleeve Ring & Pinion Master Install Kit
If you are regearing the front axle on a 1999-2016 Ford F-250 or F-350 Super Duty, or chasing a growl from a high-mileage front differential, the gears are only half the job. The bearings, shims, seal and crush sleeve have to be new too, and the Super Dana 60 under these trucks does not share every part with a conventional Dana 60. The Revolution Gear and Axle 35-2034-S is a master install kit built specifically for the Ford Super Dana 60 front axle with the crush sleeve pinion design, for use with factory-style 1999-2016 gears.
The Super Dana 60 is a reverse-rotation, high-pinion front axle. The pinion rides on two tapered bearings held in preload by a collapsible crush sleeve, and the carrier rides on two more tapered bearings that are shimmed to set backlash and side preload. When any of those bearings wear, the pinion moves and the ring and pinion pattern goes with it, which is why worn bearings eventually ruin gears. Revolution lists this kit with Timken pinion and carrier bearings, pinion and carrier shims, a crush sleeve, a pinion seal, ring gear bolts and cover gasket material. Axle seals are not included.
Front-end noise on these trucks is also commonly from wheel bearings or hubs, so rule those out with our Dana 60 front axle problems guide before opening the differential.
Three checks. First, the axle must be the Ford Super Dana 60 front, the high-pinion design with the driveshaft entering above the axle centerline. A conventional low-pinion Dana 60 front or rear uses the Revolution Dana 60 master install kit 35-2034 instead. Second, the year: 2017-up Super Duty fronts changed design and need a kit like the Yukon 2017-up Ford Dana 60 front overhaul kit. Third, Revolution states this kit is for factory-style 1999-2016 gears, so confirm your replacement ring and pinion matches that pattern. Our Dana 60 ring and pinion buyer's guide explains rotation and carrier breaks.
Revolution lists the 35-2034-S as fitting the Super Dana 60 front axle with the Ford crush sleeve design, for use with factory gear in 1999-2016 trucks. That covers the Ford F-250 and F-350 Super Duty front axle in those years, and the same axle was used under other Super Duty models. Super Duty axles saw running changes, so compare your old bearing numbers, the pinion seal and the crush sleeve style to the kit, or send us your year and VIN and we will confirm it before it ships. More heavy-duty axle parts are on our rebuild kits page.
Pair the kit with reverse-rotation gears such as the Revolution Dana 60 reverse 5.38 thick set or the Yukon Dana 60 reverse 5.13 set, and match the rear axle ratio exactly. A Dana 60 housing spreader makes carrier removal and installation far easier. Revolution's setup chart lists the Dana Super 60 with a 0.050 in starting pinion depth, 18-38 in-lb pinion bearing preload, 0.007-0.010 in backlash and 111 ft-lb on the ring gear bolts. Crush the sleeve slowly and check preload often; overshooting means starting over with a new sleeve. If you would rather avoid that, read our crush sleeve vs solid spacer guide. Use new ring gear bolts with thread locker, verify the drive and coast pattern, and fill with 75W-90 or 75W-140 gear oil. Plan new axle seals separately since they are not in this kit, and break the gears in gently before towing.
| Brand | Revolution Gear & Axle |
| Part number | 35-2034-S |
| Fits | Revolution Gear & Axle 99-16 Ford Super Dana 60 Front Crush Sleeve Ring & Pinion Master Install Kit |
| 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. It is the install kit only: Timken pinion and carrier bearings, pinion and carrier shims, crush sleeve, pinion seal, ring gear bolts and cover gasket material. Gears are sold separately.
No. Revolution lists this kit for the 1999-2016 Super Dana 60 front with the crush sleeve design. 2017-up Super Duty front axles need a different kit.
No. Those are conventional Dana 60 axles. Use the standard Dana 60 master install kit (35-2034) for them.
No. Revolution lists axle seals as not included, so order them separately if your truck needs them.
Revolution's chart for the Dana Super 60 lists 18-38 in-lb pinion bearing preload, 0.007-0.010 in backlash, a 0.050 in starting pinion shim and 111 ft-lb ring gear bolts. Always confirm the contact pattern.
75W-90 or 75W-140 gear oil. Check the fill level at the fill plug and change the oil after the first few hundred break-in miles.
