Yukon Gear 1541H Alloy Replacement Rear Axle 31-33.5in Applications for Dana 60 70 & 80
A twisted spline, a cracked flange or a shaft that snapped at the hub on a one-ton truck usually means the rear axle in a full-floating Dana 60, Dana 70 or Dana 80 has reached its limit. Yukon part YA FF35-33.5 is a 1541H alloy full-float rear shaft with 35 splines, made to cut down for applications from 31 to 33.5 inches long. It is the common choice for heavy-duty Ford, Dodge and GM truck rears and for custom-width builds that run a 35-spline carrier.
In a full-floating rear, the wheel rides on its own pair of hub bearings on the spindle at the end of the housing. The axle shaft does not hold the truck up; it only transmits torque from the carrier side gear to the hub through a bolted drive flange. That is why a full-float truck can still roll on a broken shaft once the shaft is pulled, and why the shaft is removed from the outside by unbolting the flange without opening the differential.
Because the shaft only carries twisting load, strength comes down to material and spline count. 1541H is a higher-strength alloy than the plain carbon steel used in many factory shafts, and 35 splines spread the load across more teeth than the 30 and 32 spline designs found in lighter versions of the same axle families.
Pull the shaft. On a full-float rear that means removing the flange bolts or nuts, then sliding the shaft out. Count the splines at the inner end, measure the overall length from the flange face to the spline tip, and count the flange bolts and measure the bolt circle. Check the side gear for chipped splines too, because a damaged side gear will ruin a new shaft. Our Dana 60 rear axle problems guide explains what else to check in the housing while it is apart.
This shaft is listed for Dana 60, 70 and 80 full-float rears with a 35-spline carrier, an 8-bolt drive flange on a 3.96 in. bolt circle, and a finished length anywhere from 31 to 33.5 inches. It is supplied long so it can be cut to your exact length, which is why it covers several truck makes rather than one factory part number. Before ordering, confirm your original shaft has 35 splines, 8 flange bolts and a length inside that range; a 30-spline carrier needs a different shaft, such as the 30-spline Dana 60 shaft for 34-36.5 in. applications, so match the spline count first and the length second. If you are not sure, send us your year, make, model and the measurements and we will check it.
Cutting to length should be done by a shop with the tooling to cut and re-spline or finish the shaft square; a crooked cut or a rough spline end will load the side gear unevenly. Clean the flange mating face and the hub, fit a new hub gasket or sealant where the design calls for it, and torque the flange fasteners to the factory specification for your axle. Inspect the hub bearings and seals while the hub is accessible.
If the carrier side gears are worn, rebuild the center at the same time. For a Dana 60 that means the Dana 60/61 rear master overhaul kit; a Dana 70-U master overhaul kit or a Dana 80 master overhaul kit covers the bearings and seals, and our full-float versus semi-float guide explains why these shafts are not interchangeable with semi-float parts. Refill with 75W-90 or 75W-140 gear oil as your axle requires, adding friction modifier if a limited slip is installed.
| Brand | Yukon Gear & Axle |
| Part number | YA FF35-33.5 |
| Fits | Yukon Gear 1541H Alloy Replacement Rear Axle 31-33.5in Applications for Dana 60 70 & 80 |
| Type | Axles |
| 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.
It fits Dana 60, 70 and 80 full-float rears that use a 35-spline carrier and an 8-bolt flange on a 3.96 in. circle. It is a cut-to-length shaft, so it must be cut and finished to your exact length between 31 and 33.5 inches before install.
No. Semi-float shafts carry the wheel bearing and the weight of the truck, and they use a different outer end. This shaft is for full-floating housings only.
The listing is for a single shaft. Most owners replace only the broken side, but if both shafts have high miles or you are adding a locker or bigger tires, replacing the pair keeps the strength even.
No. 1541H is a strong alloy upgrade over many factory shafts. 4340 chromoly is a step higher again and is aimed at very large tires and hard off-road use.
Inspect the carrier side gear splines, the hub bearings and seals, and the flange gasket surface. A chipped side gear or a dry hub bearing will cause a new shaft to fail or leak.
