Yukon Gear Master Overhaul Kit For Dana 60 and 61 Front Diff

A front Dana 60 that whines in four-wheel drive, clunks when the hubs are locked, or weeps gear oil from the pinion seal onto the front driveshaft has worn bearings or seals in the center section. This Yukon Gear and Axle YK D60-F master overhaul kit holds the bearings, races, seals and setup hardware for the front Dana 60 and Dana 61 found under three-quarter and one-ton Ford, Dodge and Chevrolet 4x4 trucks. Use it to freshen a noisy stock axle or as the full install kit when you regear for bigger tires.

What the master overhaul kit does in a front Dana 60

The Dana 60 runs a 9.75-inch ring gear driven by a pinion that sits on two tapered roller bearings. Pinion bearing preload is held by a crush sleeve and pinion nut, and the carrier sits on two more tapered bearings with shims behind them that set backlash and carrier preload. A shim under the inner pinion race sets pinion depth. Once any of those bearings wears, the pinion moves under load, the contact pattern walks off the teeth, and the gears start to howl. Per the Yukon parts list, this kit replaces the carrier bearings and races, pinion bearings and races, pinion seal and axle seals. It also includes a complete shim kit, ring gear bolts, pinion nut, crush sleeve, oil baffles and slingers, thread locker, gear marking compound with a brush and the cover gasket. The bearings and races are Timken.

Symptoms this kit fixes

• A whine or howl from the front axle that only shows up with four-wheel drive engaged and changes between throttle and coast
• A rumble from the front center section at road speed when the front driveshaft turns, such as with locking hubs left engaged or full-time hubs
• Gear oil seeping from the pinion seal onto the front yoke
• Wet inner axle tubes from failed inner axle seals
• Slack or a clunk when 4WD loads up, from loose pinion bearings
• Bearing flakes or a metallic sheen in the old gear oil

How to confirm it before you buy

Separate the front axle from the rest of the driveline. If the noise only happens in four-wheel drive, the front axle or front driveshaft is the source. A noise that changes when you turn usually points to the wheel bearings or ball joints at the knuckle, which this kit does not cover. For those, the Dana 60 front wheel bearing and seal kit is the right part. With the cover off, rock the pinion yoke up and down; any play means the pinion bearings are worn. Check backlash with a dial indicator and paint the ring gear to read the pattern before you tear it down.

Fitment

This kit is for the front Dana 60 and Dana 61. The front Dana 60 has been used in 1977-1991 Chevrolet one-ton 4x4s, 1975-2002 Dodge three-quarter and one-ton 4x4s, and optionally in Ford F-250 and F-350 Super Duty trucks. The Dana 61 is a version with a different pinion offset built for taller gear ratios in some 1970s and 1980s Ford and Dodge trucks. Front Dana 60s came in kingpin and ball joint versions and in standard and reverse rotation, and the 2017-and-later Super Duty short reverse front uses its own YK D60SR kit. Read the axle tag on the passenger side of the housing and send us your year, VIN and tag number if you have any doubt. More axle parts are on the hard parts page.

Install notes

• Mark the old gear pattern before teardown so you have a baseline.
• The Dana 60 carrier is a tight fit. Spread the housing just enough to lift it out using a Dana 60 housing spreader, and never spread it past the factory limit.
• A clamshell carrier and pinion bearing puller makes removing the old bearings much easier without damaging the shims you need to measure.
• Start pinion depth with your original shim, then adjust from the pattern. Use the new crush sleeve and pinion nut and tighten in small steps while checking rotating torque.
• Install the new oil baffles and slingers and the inner axle seals before you slide the axle shafts back in.
• Refill with the gear oil grade in your owner's manual. A limited slip or locker may need friction modifier.

What bearing brand is in this kit?

The YK D60-F uses Timken carrier and pinion bearings and races, along with Yukon seals and small parts.

Does it include the inner axle seals?

Yes. The parts list includes axle seals along with the pinion seal, oil baffles and slingers. Wheel bearings and knuckle parts are not included.

Will it fit my 2018 F-250 front axle?

No. The 2017-and-later Super Duty front is a short reverse Dana 60 with its own kit, the YK D60SR. Send us your axle tag if you are unsure.

Can I use this kit when I regear?

Yes. It includes the bearings, races, complete shim kit, crush sleeve, ring gear bolts and marking compound you need to set up a new ring and pinion.

Is this the same kit as the rear Dana 60 kit?

No. The front and rear Dana 60 use different parts, so the rear axle takes its own kit, the YK D60-R.