Yukon Gear Hardcore Drive Flange Kit For Dana 60 / 35 Spline Outer Stubs. Yukon Engraved Caps

Big tires, a locker and a 35-spline Dana 60 up front put more torque through the outer stubs than most factory locking hubs were built to hold. When a hub starts slipping, clicking or letting go on the trail, many owners stop replacing hubs and bolt on drive flanges instead. Yukon Gear & Axle YHC50005 is a pair of Hardcore drive flanges for Dana 60 front axles with 35-spline outer stubs, with Yukon-engraved caps and all the hardware to bolt them on. Yukon builds the kit to replace internal manual locking hubs and harden the front driveline against damage.

How the flange works on a 35-spline Dana 60

The 35-spline outer stub is the larger of the two Dana 60 stub sizes, and it is the spline count used by most chromoly front axle upgrade kits. On a hub-equipped axle, the stub reaches through the spindle to a hub assembly that can lock the wheel to the shaft or let the wheel spin free. The drive flange is a one-piece steel coupling: it slides onto the 35 splines of the stub and bolts directly to the wheel hub, so the wheel and axle shaft are locked together full-time. With no moving clutch parts inside, there is nothing to cam out, wear a spring or pack with mud.

Full-time engagement has a cost. The front driveshaft, carrier, U-joints and stubs will spin any time the truck is moving, including on the highway in 2WD. That adds some wear and noise and a slight drop in mileage. Trucks that are driven mostly on pavement are often better served by the Yukon Hardcore 35-spline locking hub set.

Signs your hubs are the weak link

• Hub that slips out of engagement on a hard climb or when the tires load up in a rut
• Loud bang or click from one front corner followed by loss of drive on that side
• Hub dial that binds, will not reach LOCK, or turns without doing anything
• Broken or twisted internal parts found when the hub is opened
• Front axle recently upgraded to 35-spline chromoly shafts and the hubs are now the weakest part

Confirm the problem first

Put the transfer case in 4WD, lock the hubs, lift a front tire and turn it by hand. A healthy corner will drag the driveshaft with it. If the tire spins on its own, open that hub and inspect the driver, the stub end and the snap ring. Also grab the stub and check for play; Yukon's Dana 60 hub guide warns that a worn spindle-to-axle bearing causes engagement trouble, and a flange will not fix that. Rule out a failed U-joint while you are there. Our locking hubs not engaging guide has the step-by-step, and the Dana 44 and Dana 60 manual hub buyer's guide compares hub and flange options.

Fitment

This kit fits Dana Spicer 60 front axles with 35-spline outer axles. Yukon's technical note excludes 1986-1989 Dodge front axles and 2005-and-later Ford Super Duty. Spline count is the deciding factor, because 30- and 35-spline Dana 60 fronts were both used across GM, Ford and Dodge one-tons. Count the splines on your stub; if you find 30, order the 30-spline Hardcore flange kit. For 1985-1998 Ford F-250 and F-350 owners, the Revolution Dana 60 35-spline flange kit is another option. Not sure what you have? Send us the year, the VIN and your spline count. Browse more Dana 60 parts in rebuild kits and axle parts.

Install notes

• Remove the old hub or flange per the factory manual and keep the stub snap ring and any spacer that belongs to the axle.
• Check wheel bearing condition and adjustment while the hub is open; repack or replace as needed.
• Clean all rust, old grease and burrs from the hub and stub splines and coat them with high-pressure grease.
• Slide the flange onto the 35-spline stub, seat the snap ring fully in its groove, bolt the flange to the hub with the supplied hardware and install the engraved cap.
• With the wheel lifted, turning the tire must turn the front driveshaft.

If you are building the axle for big tires, do the stubs and inner shafts at the same time: the Yukon 4340 chromoly 35-spline axle kit for the 1985-1988 Ford Dana 60 is one example. If the carrier bearings are tired, the Dana 60 front master overhaul kit covers them, and the front diff takes 75W-90 or 75W-140 gear oil.

How do I know if my Dana 60 has 35-spline stubs?

Count the splines on the end of the outer stub shaft with the hub or flange removed. Dana 60 fronts were built with both 30- and 35-spline stubs, so the count is the only reliable check. Most chromoly upgrade axle kits are 35-spline.

Which trucks does Yukon say this kit will not fit?

Yukon's technical note says it will not work on 1986-1989 Dodge front axles or on 2005-and-later Ford Super Duty. For anything else, match the 35-spline stub count, or send us the year and VIN.

What is included?

Two drive flanges, two Yukon-engraved caps and the hardware needed to install them. Wheel bearings, seals and the axle snap rings are not included.

Do drive flanges hurt highway driving?

The front axle parts and front driveshaft spin all the time, so there is a little more noise, front-end wear and fuel use. The transfer case still controls 2WD and 4WD. If the truck is mostly a highway vehicle, locking hubs may suit it better.

Should I upgrade the axle shafts at the same time?

If you run large tires or a locker, yes. Flanges remove the hub as a weak link, so the stubs and U-joints take the load next. Chromoly 35-spline axle kits are the usual pairing.