Yukon Gear Master Overhaul Kit For Dana 44 IFS Diff For 92+

Owners of a mid-1990s Ford F-150 or full-size Bronco 4x4 know the Twin-Traction Beam front end: great ride, but the Dana 44 in the middle of it eventually starts to hum, leak at the pinion or spit gear oil past the axle seals. This Yukon Gear and Axle YK D44-IFS-L master overhaul kit is made for the later Dana 44 independent front differential, the version Yukon lists as fitting 1993 and up. It brings every bearing, race, seal and shim you need to rebuild that center section in one order.

What the master overhaul kit does in a Dana 44 TTB front

Ford's TTB front axle is built by Dana with no full axle tubes. The differential is offset toward the driver side and bolts to the driver-side beam, which also works as the cover, while a slip yoke on the long passenger shaft lets it change length as the beams swing. Inside, the Dana 44 works like any other: the pinion rides on two tapered bearings under crush-sleeve preload and the carrier spins on two side bearings with shims setting backlash. Because the beams flex, worn bearings and dry seals show up as noise and leaks sooner than on a solid axle. This kit replaces the carrier and pinion bearings and races with Timken parts and adds the pinion seal, axle seals, a complete shim kit, ring gear bolts, pinion nut, crush sleeve, oil baffles and slingers, thread locker, marking compound with brush and a gasket.

Symptoms this kit addresses

• Front-end whine with the hubs locked and 4WD engaged that fades in 2WD
• Growl from the driver side of the front end that follows road speed
• Gear oil on the front driveshaft flange from a tired pinion seal
• Wet axle seal areas where the shafts leave the carrier housing
• Low fluid level found at service with no obvious outside leak
• Metal paste on the fill plug or in the drained oil

How to confirm the diff is the problem

Unlock the hubs and drive in 2WD at the same speed. If the noise goes away, the front differential or front driveshaft is the likely source. If it stays, look at wheel bearings and the rear axle first. On the TTB, bad beam pivot bushings and ball joints cause clunks and tire wear, not a steady gear whine, so do not confuse the two. With the front driveshaft off, rock the pinion flange to check for play and measure backlash with a dial indicator before teardown so you know where the old setup sat.

Fitment

Yukon's description for this kit states it fits the 1993-and-up Dana 44 IFS. Retail fitment for the same part number lists the 1993-1996 Ford Bronco and F-150. Ford used TTB front axles on the F-150 into the 1997 model year, so confirm a 1997 truck before ordering. Our listing title says 92 and up, but the manufacturer fitment begins at 1993; a 1992-and-earlier TTB Dana 44 takes a different, earlier overhaul kit. Read the Dana tag on the carrier or send us your year and VIN and we will match it. Other axle kits are on the rebuild kits page.

Install notes

• Record backlash and paint the gears to save the original pattern before pulling the carrier.
• Remove the carrier bearings with a side bearing puller set so the shims stay intact for measuring.
• Check the slip yoke and the passenger-side shaft U-joint while the axle is apart, since a worn joint makes noise that sounds like a bad diff.
• If the outer stub shafts are pitted at the seal or bearing surface, replace them now; a Dana 44 IFS outer stub axle is listed separately.
• A spindle with a worn bearing bore or bent snout will eat the new outer seals; a replacement front spindle for 1993-up non-ABS Dana 44 IFS is available.
• Use the new crush sleeve, bring pinion preload up slowly and do not back the nut off once it is set.
• Fill with the gear oil grade and amount in your Ford owner's manual and recheck the level after a short drive.

Does this kit fit a 1997 F-150?

Ford used TTB front axles on the F-150 through 1997, but the retail fitment for this kit lists 1993-1996. Send us your VIN or the Dana tag numbers so we can confirm before you order.

My listing says 92 and up. Will it fit a 1992 Bronco?

Yukon's fitment starts at 1993. For a 1992-and-earlier Dana 44 TTB front, you need the earlier Dana 44 IFS overhaul kit built for 92-and-older axles; contact us and we will point you to it.

What brand are the bearings?

Timken. The kit uses Timken carrier and pinion bearings and races with Yukon seals and small parts.

Does it include U-joints or ball joints?

No. It covers the differential center section only: bearings, races, seals, shims, crush sleeve, pinion nut, ring gear bolts, baffles and slingers, thread locker, marking compound and a gasket.

Should I change gear ratio while it is apart?

Only if you also change the rear axle ratio to match. The front and rear ratios on a 4x4 must be the same or the transfer case and tires will bind in 4WD.