Revolution Gear & Axle Dana 60 Reverse Rotation Front Axle 5.38 Ratio Thick Ring & Pinion Set
The Revolution Gear & Axle D60-538RT is a 5.38 ring and pinion for the reverse rotation Dana 60 front axle under Ford F-250, F-350 and F-450 trucks. The people who order it have usually just put 37 to 40 inch tires on a Super Duty, re-geared the rear, and now need a matching front. What makes this set different from most deep front gears is the thick ring gear: it is built to bolt onto the carrier that came in trucks with 3.73 or 4.10 gears, so you can go to 5.38 without buying a new carrier or locker at the same time.
On these Ford fronts the pinion enters the housing above the axle centerline. That keeps the front driveshaft high, but it also means the ring gear turns the opposite way from a rear axle, so the gear teeth must be cut for reverse rotation. A standard rotation set installed here would drive on the coast side of the teeth and fail early. At 5.38 the driveshaft turns 5.38 times for every turn of the wheels, putting a lot of torque back at a tall tire. Revolution lists this set with a 9.75 inch ring gear, a 29-spline pinion, twelve 1/2 inch ring gear bolts, a 10-bolt cover and 8620 steel construction.
The thick ring gear is the whole point of this part number. Dana 60 carriers come in two breaks, with the change between 4.10 and 4.56. Deep ratios normally need the 4.56-and-up carrier because the pinion head gets smaller and the ring gear has to sit closer to it. A thick gear adds that material to the ring gear itself, so it mounts on the 4.10-and-numerically-lower carrier instead.
Read the ratio from the axle tag or the stamping on the ring gear, and confirm the pinion enters high in the housing. Then identify your carrier: if the axle left the factory with 3.73 or 4.10 gears, this thick set is the one that fits it. If it already has a 4.56-or-deeper carrier, the standard-thickness Yukon D60 reverse rotation 5.38 set matches that carrier instead. Our Dana 60 ring and pinion buyer's guide walks through rotation and carrier break, and finding your axle ratio and axle code shows where the tag lives. Front and rear must end up with the same ratio, so order both ends together.
Revolution lists this gear set for the reverse rotation Dana 60 front in 1978-1979 Ford F-250, 1978-1997 F-350, 1999-2015 F-350 Super Duty, 2002-2015 F-250 Super Duty and 2000-2014 F-450 Super Duty. Trucks in that range were built with different front axles and carriers depending on drivetrain and options, so check the axle tag, count the twelve ring gear bolts and confirm the 29-spline pinion against your old parts. If you are unsure, send us your year and VIN before ordering. More Dana 60 parts are in our hard parts collection, and common failure points on this axle are covered in Dana 60 front axle problems and rebuild cost.
This listing is the ring and pinion only. Plan on new pinion and carrier bearings, races, shims, a pinion seal and ring gear bolts; for 1999-2016 Super Duty fronts the Revolution Super Dana 60 front master install kit covers that list. With the axle shafts out, set pinion depth first, then pinion bearing preload, then carrier backlash, and confirm everything with a contact pattern using marking compound on both sides of the teeth. Reverse rotation gears read their drive pattern on the opposite side from a rear axle, so do not chase the pattern you are used to seeing. Fill with 75W-90 or 75W-140 gear oil, take it easy for the first few hundred miles with no towing and no heavy 4WD loads, and change the oil after break-in. While the hubs are apart it is a good time to replace worn Dana 60 front wheel bearings and seals.
| Brand | Revolution Gear & Axle |
| Part number | D60-538RT |
| Fits | Revolution Gear & Axle Dana 60 Reverse Rotation Front Axle 5.38 Ratio Thick Ring & Pinion Set |
| Type | Ring & Pinions |
| 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.
Yes, that is what the thick ring gear is for. Revolution lists the D60-538RT for Dana 60 reverse rotation carriers built for 4.10 and numerically lower ratios, so a 3.73 or 4.10 factory carrier can stay.
No. This is a reverse rotation set for the high-pinion Ford front axle. A rear Dana 60 uses standard rotation gears.
It is a common choice for heavy Super Duty trucks on roughly 37 to 40 inch tires, but the right ratio depends on engine, transmission and use. Match the front to whatever ratio you put in the rear.
No, it is the gear set only. Add a master install kit with pinion and carrier bearings, races, shims, seal and ring gear bolts.
75W-90 or 75W-140 gear oil. Change it after the first few hundred break-in miles to flush out the wear particles from the new teeth.
Ratio and rotation are the same. The non-thick set needs the 4.56-and-up carrier, while this thick set bolts to the 4.10-and-down carrier.
