Yukon Gear High Performance Replacement Gear Set For Dana 30 in a 5.38 Ratio
5.38 is the deepest ratio most people will ever put in a Dana 30, and the buyers who search for it are usually building a crawler: a CJ7 or Scrambler on big tires with a 5.38 rear already ordered, an International Scout that needs its front to match, or an early Bronco geared low for rocks and slow trails. The Yukon Gear & Axle YG D30-538 is a new 5.38 ring and pinion for the standard-rotation, low-pinion Dana Spicer 30 that preloads its pinion with shims instead of a crush sleeve.
Yukon's listing gives this set a 7.20 in. ring gear, a 26-spline pinion and 10 ring gear bolts. With 5.38 gearing the driveshaft turns 5.38 times for each wheel revolution, which multiplies torque about 44 percent over a 3.73, 18 percent over a 4.56 and 10 percent over a 4.88. That is what lets an engine pull 35 in. tires at a walking pace without slipping the clutch. The trade-off is physical: the deeper the ratio, the smaller the pinion head has to be inside the same 7.20 in. ring gear, so a 5.38 Dana 30 has less tooth to spare than a 4.11 in the same housing. Yukon's own install manual lists 33 in. as its maximum recommended tire diameter for the Dana 30, so a front axle running bigger tires than that needs a light right foot and careful use of the locker.
Count teeth on the ring gear and pinion or read the axle tag to learn the current ratio, and confirm the rear axle will be 5.38 too. Then confirm the axle type: this set is for the standard-rotation Dana 30 with the pinion below center. The YJ front is a reverse-cut axle, and TJ and late XJ fronts use a short-pinion design that takes different gears. Our Dana 30 front axle problems guide lists the wear points to check while it is apart, and regearing after bigger tires walks through choosing between 4.88 and 5.38 for your tire size and transmission.
Yukon's application table lists this set for the Dana 30 front in the 1971-1983 Jeep CJ5, 1971-1975 CJ6, 1976-1986 CJ7, 1981-1986 Scrambler, 1972-1973 Jeepster Commando and 1971-1973 Wagoneer, plus the 1966-1971 Ford Bronco, 1967-1971 Scout 800, 1971-1974 Scout II and the 1980-1988 AMC Eagle. These axles were built in small batches over many years and not every one matches the catalog, so confirm pinion position and the axle tag, or send us your year and VIN before you order. If 5.38 turns out to be too deep, the same axle takes our Yukon Dana 30 4.27 set or Yukon Dana 30 4.11 set. For a full rebuild on a budget, the USA Standard ZK D30-F master overhaul kit fits the same axle.
The 5.38 ring gear bolts to the 3.73-and-numerically-higher Dana 30 carrier. An axle that left the factory with 3.54 or lower gears needs a Dana 30 3.73-up open carrier case or a locker made for that carrier break.
New bearings and races are part of the job, not an option. The Dana 30 front master bearing kit with Timken bearings covers pinion and carrier bearings, races, shims and seal. Yukon's setup chart gives the Dana 30 a starting pinion shim of 0.065 in., 12-15 in-lb of preload on new pinion bearings and 60 ft-lb on the bearing caps. Mark the caps left and right, set pinion depth first, then preload and backlash, and read the pattern on both drive and coast sides with marking compound. Fill with 75W-90 GL-5 gear oil. Yukon's break-in steps are simple: drive lightly for the first 15 to 20 miles and let the axle cool, avoid hard acceleration for 100 miles, and wait at least 500 miles before heavy use, then change the oil.
| Brand | Yukon Gear & Axle |
| Part number | YG D30-538 |
| Fits | Yukon Gear High Performance Replacement Gear Set For Dana 30 in a 5.38 Ratio |
| Type | Final Drive Gears |
| 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.
Yes. In 4WD the transfer case locks the front and rear driveshafts together, so a 5.38 front must run with a 5.38 rear. A mismatch causes binding and can damage the transfer case.
No. The YJ front is a reverse-rotation Dana 30 and the TJ and late XJ use a short-pinion Dana 30. This YG D30-538 is for the standard-rotation axle found in CJs, Scouts and early Broncos.
No. The 5.38 ring gear fits the Dana 30 carrier for 3.73 and numerically higher ratios. An axle with 3.54 or lower gears needs a 3.73-up carrier or locker.
It is mostly used with 35 in. and larger tires on crawlers. Yukon's manual lists 33 in. as its maximum recommended tire for the Dana 30, so bigger tires on this axle call for careful throttle and locker use.
All pinion and carrier bearings and races, the pinion seal, shims and ring gear bolts. A Dana 30 master bearing kit covers these. Check axle u-joints and inner seals while the shafts are out.
