Revolution Gear & Axle Dana 60 Front/Rear Axle Ring & Pinion Master Install Kit
Anyone regearing or rebuilding a Dana 60 in a 3/4-ton or 1-ton truck, a Ram or Ford heavy-duty, a GM HD or a built Jeep needs the same pile of bearings, shims and hardware before the new gears can go in. The Revolution Gear and Axle 35-2034 master install kit puts that in one box for the standard Dana 60, front or rear. It is the kit to order alongside a new ring and pinion, or on its own when a whining Dana 60 has worn bearings but the gears themselves are still good.
A ring and pinion only lives as long as the bearings that hold it in position. The pinion rides on two tapered bearings loaded by a crush sleeve, and the carrier rides on two more, with shims setting pinion depth and carrier side position. Reusing old bearings or shims on new gears is the most common reason a fresh regear starts howling. According to Revolution, kit 35-2034 includes Timken pinion bearings and carrier bearings, a pinion seal, crush sleeve, carrier shims, pinion shims, ring gear bolts and cover gasket or silicone. Axle seals are not included, so order those separately if the shafts are coming out.
Pull the cover, check the oil for metal and rock the pinion yoke up and down; play there means pinion bearings. Rotate the carrier and feel for roughness. Our Dana 60 rear axle problems guide and Dana 60 front axle problems guide break down noises, wear points and what a rebuild costs. If you are changing ratio at the same time, read the Dana 60 ring and pinion buyers guide first so the gear, rotation and carrier break match before you buy the kit.
Revolution lists this kit for Dana 60 front and rear differentials; its online vehicle chart only names a handful of 1960s GM trucks, so treat the axle itself as the fitment check. Dana 60s were used for decades in Ford, Dodge and Ram, Chevrolet and GMC heavy-duty trucks, and there are important exceptions. The 1999-2016 Ford Super Dana 60 front uses Revolution's separate 35-2034-S Super 60 kit, and 2017-up Ford fronts use a different kit again. Some Dodge rears use a dual pinion seal setup that Revolution kits separately. Confirm the axle tag, the 12-bolt ring gear pattern and that you have a crush-sleeve Dana 60, or send us your year and VIN. More kits are in our rebuild kits category.
Revolution's Dana 60 setup numbers are 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 ring gear bolts and 80 ft-lb bearing caps. Carrier bearings on a Dana 60 are tight, so a Dana 60 housing spreader makes removing and installing the carrier with shims much easier and safer for the housing. Press the bearings on with proper adapters, crush the sleeve gradually and check preload often; going past spec means starting over with a new sleeve. Read the contact pattern before final assembly. If the gears are being replaced, the Revolution D60 3.55 ring and pinion is one option for standard-rotation axles; deep-ratio thick sets such as the Yukon D60 4.88 thick set also install with this kit. Fill with 75W-90 or 75W-140 GL-5 (non-synthetic during gear break-in if new gears went in) and add friction modifier for a clutch-type limited slip. Inspect the spider gears while the carrier is out, and the Dana 44 vs Dana 60 front guide is worth a look if you are deciding whether to upgrade instead of rebuild.
| Brand | Revolution Gear & Axle |
| Part number | 35-2034 |
| Fits | Revolution Gear & Axle Dana 60 Front/Rear Axle 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.
Per Revolution: Timken pinion and carrier bearings, pinion seal, crush sleeve, carrier shims, pinion shims, ring gear bolts and cover gasket or silicone. Axle seals are not included.
No. The 1999-2016 Ford Super 60 front uses the 35-2034-S kit, and 2017-up Ford fronts use a different kit. This 35-2034 is for the standard Dana 60.
Yes, Revolution lists it for Dana 60 front and rear differentials. Order one kit per axle, and confirm each axle is a standard crush-sleeve Dana 60 before ordering.
You should. Used bearings carry the old wear pattern and preload, and they are the most common cause of a new gear set whining. New bearings, sleeve and shims are cheap insurance on a job this labor intensive.
Revolution lists a 0.052 inch starting pinion shim, 17-30 in-lb preload, 0.006-0.010 inch backlash, 110 ft-lb ring gear bolts and 80 ft-lb caps. Always verify with a contact pattern.
75W-90 or 75W-140 GL-5 for a Dana 60, with friction modifier for a clutch-type limited slip. If new gears went in, use a non-synthetic GL-5 for break-in and change it at 500 miles.
