Yukon Gear High Performance Gear Set For Dana 60 in a 4.88 Ratio / Thick

The Yukon YG D60-488T is a 4.88 ring and pinion for standard rotation Dana 60 axles: the rear Dana 60 used in decades of Ford, GM and Dodge 3/4-ton and 1-ton trucks and vans, the Dana 60 rear in classic Mopar muscle cars, and the low-pinion front Dana 60 under 1994-2002 Ram 2500 and 3500 4x4s. Buyers land here after adding 35 to 37 in. tires to a heavy truck, after building a tow rig or crawler that needs more low-end, or when worn factory gears have started to howl.

What the ring and pinion does in a standard rotation Dana 60

In a standard rotation axle the pinion sits below the axle centerline and the ring gear turns the same way as a conventional rear axle, so the drive side of the teeth carries the load going forward. The 4.88 ratio turns the pinion 4.88 times per wheel revolution, a big jump from the 3.54, 3.73 and 4.10 ratios most of these vehicles came with. Yukon cuts this set with a 9.75 in. ring gear, 12 ring gear bolts and a 29-spline pinion. The T means thick: the ring gear is made thicker so a deep ratio still fits the 3-series carrier designed for 4.11 and numerically lower gears.

Symptoms

• Whine on the highway that changes pitch between load and coast
• Gear noise plus a growl that rises with speed, a sign that bearings are failing alongside the gears
• Poor acceleration, high transmission temperatures and constant hunting between gears after a tire upgrade
• Pitted, scuffed or chipped teeth found during a fluid change
• Gear oil leaking from the pinion seal and a wet yoke, which often follows pinion bearing wear

How to confirm before you buy

Confirm three things: that the axle is a Dana 60 and not a Dana 70 or 11.5, that the pinion is low (standard rotation), and what ratio and carrier are in it now. The Dana 60 ring and pinion buyer's guide explains the carrier break, and Dana 60 rear axle problems and rebuild cost helps you sort gear noise from bearing and seal problems.

Fitment

Yukon's fitment list runs from 1960s Ford, Dodge and GM trucks through recent vans. Examples include the 1994-2002 Ram 2500 and 3500 rear and the 1994-2002 Ram 2500 and 3500 front disconnect-design Dana 60, 1974-1986 F-250 rears, 2003-2014 Ford E-250 and 2000-2015 E-350 Super Duty vans, 2003-2009 Chevrolet Express 2500/3500, 2002-2005 GM Quadrasteer rears, K30 and V30 trucks, and Dodge Charger, Dart and Plymouth Road Runner and Barracuda Dana 60s. Every listing notes it fits the 3-series carrier, so an axle that came with 4.11 or lower gears keeps its case or locker. Reverse rotation Ford fronts need a different set, such as the 5.38 reverse rotation set. If you are unsure of your axle, send the year and VIN and we will check it.

Install notes

• Yukon's chart for the D60, 61 and 70U calls for a 0.052 in. starting pinion shim, 17-30 in-lb on new pinion bearings, 110 ft-lb ring gear bolts and 80 ft-lb caps.
• Replace both pinion bearings, carrier bearings, races and the seal. The Yukon Dana 60/61 rear master overhaul kit has the parts for a rear, and the Dana 60 carrier bearing kit covers the carrier side on its own. For a front axle, the Revolution Dana 60 front/rear master install kit is another complete option.
• Use the contact pattern, not just backlash numbers, to finalize pinion depth. Our backlash and pinion depth setup guide shows the patterns to look for.
• Fill with 75W-90 or 75W-140 gear oil (add friction modifier if the axle has a clutch-type limited slip), skip towing for the first 500 miles and change the oil at 500 miles, following Yukon's break-in guidance and our ring and pinion break-in procedure.

What does thick mean on this Dana 60 gear set?

The ring gear is made thicker so a 4.88 ratio mounts on the 3-series carrier used with 4.11 and lower ratios. You do not need a 4.56-and-up carrier for this set.

Will this fit a Ford Super Duty front Dana 60?

No. Ford Dana 60 fronts are reverse rotation (high pinion). This is a standard rotation set for Dana 60 rears and low-pinion fronts such as the 1994-2002 Ram 2500 and 3500.

Do I need to change both axles on a 4x4?

Yes. Front and rear ratios must be identical. A Ram with Dana 60 front and rear could use this set in both axles if both are standard rotation.

What should I replace with new gears?

Pinion and carrier bearings, races, the pinion seal, crush sleeve or shims, and ring gear bolts. A Dana 60 master overhaul kit covers all of them.

How do I break in a 4.88 Dana 60?

Drive gently with no towing for the first 500 miles, then drain and refill with fresh 75W-90 or 75W-140 gear oil to flush out wear-in material.

What tires is 4.88 suited for?

4.88 is a common choice for 35 to 37 in. tires on heavy trucks and for tow rigs and crawlers. Check our regear guidance for your exact tire size and transmission.