Revolution Gear & Axle Dana 80 Rear Axle 3.55 Ratio Ring & Pinion Set
The Revolution Gear & Axle D80-355 is a 3.55 ring and pinion for the Dana 80 full-floating rear axle, the one under dually and heavy one-ton Ford F-350 and F-450 trucks, 1994-2002 Ram 2500 and 3500 diesels, GM C3500 and K3500 trucks and Express, E-series and Econoline vans. Buyers usually land on this set for one of two reasons: the original gears have started to howl after hundreds of thousands of towing miles, or the truck runs a numerically high ratio and the owner wants lower highway rpm for long empty runs. A 3.55 is the tallest ratio in Revolution's Dana 80 line, which runs 3.55 through 5.13.
Revolution lists this set with an 11.25 in. ring gear held on by twelve 1/2 in. bolts, a 37 spline pinion, 8620 steel and standard rotation for a rear axle. Because the Dana 80 is full floating, the axle shafts only carry torque while the hub bearings hold the truck up, so the ring and pinion and the pinion bearings take the whole load of a trailer on a grade. At 3.55 the pinion turns 3.55 times for every turn of the tires. That ratio drops cruise rpm compared with a 4.10, but it also asks more of the transmission and torque converter when you start a heavy load, so it suits trucks with tall factory gearing, stock tire size or an overdrive transmission that already gets the engine into its torque band.
Revolution gives the carrier break for this axle as 3.73/4.10. In plain terms, a 3.55 set bolts to the same 3.73-and-down carrier as a 3.73, while 4.10 and deeper ratios need the other carrier. If your truck has factory 4.10 or deeper gears, plan on a carrier or locker change with this set. Our carrier break explainer shows how to tell which case you have.
Bearing growl and gear whine are easy to confuse on a full floater. Use our accel vs decel whine diagnosis and the Dana 80 rear axle problems guide to narrow it down, then read the current ratio from the axle tag or ring gear and check the tooth contact with the cover off. If you are changing ratio, our axle ratio and axle code guide covers how to confirm what is in there now.
Revolution's fitment list for the Dana 80 3.55-5.13 set covers 1988-1997 Ford F-350, 1999-2015 F-350 Super Duty, 1999-2005 F-450 Super Duty, Ford E-350 and E-450 vans (1988-2010 by model), 1994-2002 Dodge Ram 2500 and 3500, 1999-2003 Ram 2500 Van, 1995-1998 B3500, 1990-2000 Chevrolet and GMC K3500, 1992-2000 C3500, 1996-2007 Express 3500, 1992-1995 G30, 1997-1999 P30 and 2003-2009 C4500 Kodiak. Not every truck in those years has a Dana 80, so confirm the axle tag and the 10 bolt cover. Late Ford Dana 80s also use two pinion bearing race sizes, which changes the bearing kit but not this gear set. Send us your year and VIN if you are unsure, or browse other ratios such as the Dana 80 3.73 set and more in the hard parts catalog.
The Dana 80 pinion is preloaded with shims, not a crush sleeve. Revolution's setup chart lists a 0.060 in. starting pinion depth, 25-40 in-lb pinion bearing preload, 0.004-0.010 in. backlash, 175 ft-lb ring gear bolts and 90 ft-lb bearing caps. Install new bearings with the gears using the 4.125 in. race Dana 80 overhaul kit or the 4.375 in. race kit for 1998-up Fords, spread the housing to set the carrier, fill with 75W-90 or 75W-140 gear oil and follow our ring and pinion break-in procedure before towing.
| Brand | Revolution Gear & Axle |
| Part number | D80-355 |
| Fits | Revolution Gear & Axle Dana 80 Rear Axle 3.55 Ratio 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.
The gears fit the axle, but Revolution lists the Dana 80 carrier break at 3.73/4.10. A 3.55 needs the 3.73-and-down carrier, so a truck with factory 4.10 or deeper gears needs a different carrier or locker to run this set.
It works for highway towing with a strong engine, an overdrive transmission and stock tire size. If you tow heavy in hills or run larger tires, a 3.73 or 4.10 keeps the engine in its torque band and is easier on the transmission.
Yes. New gears on old bearings rarely stay quiet. Ford Dana 80s use either a 4.125 in. or a 4.375 in. pinion bearing race, so match the kit to the race size in your axle.
Use 75W-90 or 75W-140 gear oil, adding friction modifier if the axle has a limited slip. Change it after the break-in miles because new gears shed fine metal.
Look for an 11.25 in. ring gear axle with a 10 bolt cover and a full-floating hub, then read the axle tag or door sticker axle code. Dually Ford, Ram and GM one-tons are the usual applications, but many single rear wheel trucks used other axles, so check before ordering.
