Revolution Gear & Axle Dana 60 Front/Rear Axle Koyo Ring & Pinion Master Install Kit
If the Dana 60 under your 3/4-ton or 1-ton truck, or the one bolted into a built Jeep, has started to howl on the highway, clunk on and off the throttle or weep oil at the pinion, the bearings are usually the first thing to go. The Revolution Gear and Axle K35-2034 is the Koyo-bearing master install kit for standard Dana 60 front and rear differentials. It is the hardware you need when new gears go in for bigger tires, and the full bearing overhaul when the gears are still good but the axle is noisy.
A Dana 60 uses a 12-bolt ring gear pattern, with the pinion carried on two tapered bearings and preloaded by a crush sleeve. The carrier turns on two side bearings, and shims behind them set where the ring gear sits against the pinion. Pinion depth shims set how deep the pinion reaches into the ring gear. When any of those bearings wear, preload drops, the gear mesh moves under load and the tooth contact walks off center, which is where the noise comes from. Per Revolution, K35-2034 includes Koyo pinion bearings and carrier bearings, pinion seal, crush sleeve, pinion shims, carrier shims, ring gear bolts and cover gasket or silicone. Axle seals are not included.
The difference from the 35-2034 Timken version is the bearing brand and the price; the included-parts list and fitment are the same on Revolution's pages. Koyo is a common choice for a daily-driven or work truck regear where you want quality bearings without paying the Timken premium.
Drain the oil into a clean pan, look for metal, then grab the yoke and rock it up, down, in and out. Any play means the pinion bearings are done. Turn the carrier by hand with the cover off and feel for roughness. A hum that only tracks road speed and never changes with throttle is often a wheel bearing or hub, so rule those out first. Our Dana 60 rear axle problems guide and Dana 60 front axle problems guide cover the noise checks and what a rebuild costs.
Revolution lists K35-2034 for Dana 60 front and rear axle differentials. Dana 60s went into Ford, Dodge and Ram, Chevrolet and GMC heavy-duty trucks for decades, and there are exceptions that need a different kit. The 1999-2016 Ford Super Dana 60 front uses Revolution's Super 60 crush sleeve kit, 2017-up Ford fronts use another kit again, and a Dana 61 or Dana 70 is not a Dana 60. Read the axle tag, count the cover bolts and confirm it is a crush-sleeve Dana 60, or send us your year and VIN. More axle kits are in our rebuild kits category.
Revolution's Dana 60 setup chart lists a 0.052 inch starting pinion shim, 17-30 in-lb pinion bearing preload with new bearings, 0.006-0.010 inch backlash, 110 ft-lb on the ring gear bolts and 80 ft-lb on the bearing caps. Use the shim as a starting point, then finalize from the painted contact pattern as shown in our backlash and pinion depth setup guide. Dana 60 carriers are a tight fit, and a Dana 60 housing spreader lets the carrier and shims come out without prying on the housing. A clamshell bearing puller removes the old cones cleanly. Tighten the pinion nut in small steps against the new crush sleeve and check turning torque each time; overshoot it and the sleeve has to be replaced. If you are changing ratio, a set such as the Yukon Dana 60 4.56 gear set installs with this kit. Fill with 75W-90 or 75W-140 GL-5, add friction modifier for a clutch-type limited slip, and follow the new gear break-in procedure when the gears are new.
| Brand | Revolution Gear & Axle |
| Part number | K35-2034 |
| Fits | Revolution Gear & Axle Dana 60 Front/Rear Axle Koyo 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.
Revolution lists Koyo pinion and carrier bearings, a pinion seal, crush sleeve, pinion shims, carrier shims, ring gear bolts and cover gasket or silicone. Axle seals are not included.
The K version uses Koyo bearings and the 35-2034 uses Timken bearings. Revolution lists the same Dana 60 front and rear fitment and the same included parts for both.
No. The 1999-2016 Ford Super 60 front and the 2017-up Ford front each use their own Revolution kits. This kit is for the standard Dana 60. Check the axle tag or send us your VIN.
Yes, if the teeth are not pitted, chipped or blued. Measure the original pinion shim before removing it and set preload, backlash and pattern again. Worn gears tend to stay noisy, so most owners replace them while the pinion is out.
75W-90 or 75W-140 GL-5 gear oil, with friction modifier if the axle has a clutch-type limited slip. With new gears, change the oil after the break-in miles.
