Yukon Gear High Performance Gear Set For Dana 60 Reverse Rotation in a 5.38 Ratio

The Yukon YG D60R-538R is a 5.38 ring and pinion for the reverse rotation (high pinion) Dana 60 front axle found under Ford F-250 and F-350 trucks from the late 1970s through the 1999-2015 Super Duty, plus 2000-2014 F-450 and F-550 chassis. Owners shopping for it usually have one of two problems: the truck now rides on much taller tires and the front gears no longer match a re-geared rear, or the factory front gears are whining or chipped after years of plowing, towing and off-road abuse.

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

Ford placed the front pinion high in the housing so the front driveshaft clears the oil pan and rides above rocks. Because the pinion sits above the centerline, the ring gear spins the opposite way from a rear axle, so the teeth have to be cut with the drive side facing that direction. A 5.38 ratio means the pinion turns 5.38 times for every turn of the ring gear and wheels, which multiplies torque at the tire and brings engine rpm back into its working range after a big tire upgrade. This set has a 9.75 in. ring gear, a 29-spline pinion and 12 ring gear bolts.

Symptoms that point to new front gears

• A howl from the front axle that appears only with the hubs locked and 4WD engaged, and changes between throttle and coast
• Tire scrub, hopping or binding in 4WD on pavement or hardpack because the front and rear ratios are different
• Transmission running hot and constant downshifts on grades after moving to 37 in. tires
• Metal flakes or broken tooth pieces on the drain plug magnet or in the bottom of the cover
• A clunk when 4WD loads up, which can mean a cracked tooth or loose ring gear bolts

How to confirm before you buy

Pull the cover and read the tag or the numbers stamped on the ring gear to learn your current ratio, then count the ring gear bolts and confirm the pinion enters high. Our guide on finding your axle ratio and axle code shows where to look, and the Dana 60 ring and pinion buyer's guide explains rotation and the carrier break in plain terms. Never run a front ratio that differs from the rear, even by a small amount.

Fitment

Yukon lists this set for the reverse rotation Dana 60 front on 1978-1999 F-250 4WD, 1979-1997 F-350 4WD, 1999-2015 F-250 and F-350 Super Duty (both the standard front and the 35-spline Super 60), 2000-2014 F-450 Super Duty and 2000-2013 F-550 Super Duty. The detail that separates this part from shallower ratios is the carrier: a 5.38 ring gear bolts to the 4-series carrier built for 4.56-and-up ratios. If your axle has a 3.73, 4.10 or 4.30 from the factory, you need a 4-series carrier or locker along with these gears. Buyers who want to keep the original carrier should look at the 5.13 thick reverse set, which fits the 4.11-and-down case. Not sure which axle you have? Send us the year and VIN before ordering.

Install notes

• The Yukon setup chart for the Dana 60 lists a 0.052 in. factory pinion shim, 17-30 in-lb of preload on new pinion bearings, and 110 ft-lb on ring gear bolts with 80 ft-lb on the bearing caps.
• Replace pinion and carrier bearings, races, seal and crush sleeve together. The Yukon Dana 60 front master overhaul kit or the Revolution 99-16 Super Duty front master kit covers those pieces. If the yoke's seal surface is grooved, replace it too; the Yukon Dana 60/70 1350 yoke matches this 29-spline pinion, but confirm your u-joint size first.
• Set backlash, read the contact pattern on both sides of the teeth, and adjust pinion depth until it centers. Our backlash and pinion depth guide walks through reading the pattern.
• Fill with 75W-90 or 75W-140 gear oil, drive at least 500 gentle miles before towing, and change the oil at 500 miles, as Yukon's break-in instructions require.

Yukon's manual lists 37 in. as its maximum recommended tire diameter for a Dana 60, so plan axle shafts, u-joints and steering upgrades if you are going bigger.

Will this 5.38 set bolt to my factory Ford Super Duty front carrier?

Only if the carrier is already a 4-series case for 4.56 and numerically higher ratios. Trucks that left the factory with 3.73 or 4.10 gears have the smaller carrier and need a 4-series carrier or locker to run 5.38s.

Does it fit the 2017 and newer Super Duty front axle?

No. Yukon lists this set through the 2015 model year. The 2017-up Super Duty front uses a different Dana 60 design with its own gears.

Do I have to change the rear gears too?

Yes. Front and rear ratios must match exactly or the truck binds and wears parts in 4WD. Pair this with a 5.38 set for your rear axle.

What tire size is 5.38 meant for?

Most builders use 5.38 on 37 in. and larger tires, especially with heavy trucks or towing. Yukon recommends 37 in. as the maximum for a Dana 60, so bigger tires call for stronger parts.

What gear oil and break-in does it need?

Use 75W-90 or 75W-140 gear oil. Drive at least 500 miles without towing, then change the oil to flush out wear-in metal.