USA Standard Master Overhaul Kit Dana 60 Front

A Dana 60 front axle that hums in four-wheel drive, howls on the highway even with the hubs unlocked, or leaks gear oil at the pinion or out the knuckles is due for new bearings and seals. This USA Standard Gear ZK D60-F master overhaul kit covers the differential in a Dana 60 front, the steer axle used under heavy-duty Ford, Dodge, Chevrolet and GMC 4x4 trucks and in many one-ton swap builds. It is a full service kit for a worn stock axle, and the setup kit you want when installing new gears.

What the master overhaul kit does in a Dana 60 front

The Dana 60 is a carrier-type axle with a 10-bolt cover. The pinion runs on two tapered roller bearings, held under preload by a crush sleeve and nut, and pinion depth is set with a shim under the inner race. The carrier sits on two tapered bearings with shims behind them that set backlash and side preload. Because a front axle also carries the inner axle shafts through long tubes to the knuckles, the inner axle seals near the carrier keep gear oil in the center section and dirt out. This kit uses Koyo bearings and races and includes carrier bearings and races, pinion bearings and races, pinion seal, inner axle seals, complete shim kit, ring gear bolts, pinion nut, crush sleeve, oil baffles and slingers, thread locker, marking compound with brush and gasket.

Symptoms of a worn Dana 60 front differential

• Whine or howl from the front that gets louder with speed, often worse in 4WD
• Steady growl that does not change with steering input (hub and ball joint noise usually does)
• Gear oil at the pinion seal, or oil reaching the knuckles and U-joints from failed inner axle seals
• Clunk when engaging 4WD or changing direction, from worn pinion bearings or excess backlash
• Metal glitter or chunks on the drain plug or cover

How to confirm before you buy

Drive in 2WD with the hubs unlocked; a noise that stays may still be the front differential if the axle spins with the driveshaft. Then lock the hubs and repeat. Check pinion yoke play by hand, look for oil at the knuckles, and inspect the gear teeth and bearings with the cover off. If the hubs or wheel bearings are worn too, plan for the Dana 60 front wheel bearing and seal kit on the same job.

Fitment

This kit is for the Dana 60 front differential. Dana 60 fronts were built in standard rotation (low pinion, as in GM and Dodge trucks) and reverse rotation (high pinion, as in Ford trucks), and in kingpin and ball joint versions. Check the axle tag on the housing for the Dana bill of materials number and ratio, and send it to us with the year and VIN if you want a second look. The 2017-and-later Ford Super Duty front uses its own kit, the 2017-up Ford Dana 60 front overhaul kit. For the rear axle, see the Dana 60/61 rear kit. More axle parts are on the rebuild kits page.

Install notes

• Pull the axle shafts first; on a front axle that means hubs, spindles and the shaft assemblies come out before the carrier.
• Set the oil baffles and slingers in place behind the races as you install them, so gear oil is directed to the pinion bearings.
• Start pinion depth with the original shim, then fine tune from the marking compound pattern. Use the new crush sleeve and nut, tightening in steps while checking turning torque.
• Drive the inner axle seals in square with a proper installer, such as the Dana 30/44/60 inner axle seal installer, so they are not damaged when the shafts go back in.
• Changing ratios for bigger tires? Pair the kit with a Dana 60 5.13 gear set, and match the front and rear ratios.
• Refill with 75W-90 or 75W-140 gear oil as your owner's manual specifies.

Does this kit fit a reverse-rotation Ford Dana 60 front?

The kit is listed for the Dana 60 front differential. Confirm with the Dana number on your axle tag, and note that 2017-up Ford Super Duty fronts use a separate kit.

Are the inner axle seals included?

Yes. The kit includes the inner axle seals plus carrier and pinion bearings and races, pinion seal, shims, ring gear bolts, pinion nut, crush sleeve, oil baffles and slingers, thread locker, marking compound and gasket.

Does it include wheel bearings, ball joints or U-joints?

No. It covers the differential only. Hub bearings, ball joints, kingpins and axle U-joints are separate parts.

What bearings are in the kit?

USA Standard Gear lists Koyo bearings and races for this kit.

What gear oil goes back in a Dana 60 front?

Most take 75W-90 or 75W-140. Use the grade in your owner's manual, and add friction modifier first if the axle has a clutch-type limited slip.