Yukon Gear Trac Lok Positraction internals For Dana 80 and w/ 35 Spline Axles
This is the Yukon Trac Lok positraction internals kit for the Dana 80 rear axle with 35-spline shafts, part YPKD80-P/L-35-R. It is the repair for a factory limited-slip Dana 80 that has started clunking on takeoff, grinding in turns or leaving chunks of gear on the drain plug magnet in a 1994-2002 Dodge Ram 3500, a Ford F-350 dually or F-450, or a GM C3500 HD. Instead of buying a whole new carrier, you rebuild the one you have with new gears, shafts and thrust washers.
The Dana 80 is a full-floating rear axle with an 11.25 in. ring gear, and its factory Trac Lok is unusual: it is a four-pinion unit, where most Dana Trac Lok carriers use two. The two side gears ride on the 35-spline axle shafts and the four pinion gears sit on cross shafts between them, sharing the load of a heavy truck towing or hauling. Clutch packs behind the side gears add the limited-slip bias. This kit replaces the gear train: two side gears, four pinion gears, the cross pin shafts and the side gear thrust washers. It does not include the clutch discs and steel plates, so inspect those while the carrier is apart.
Drain the oil and look at the magnet, then pull the cover. With the truck in neutral, rotate one wheel and watch the side and pinion gears for chipped teeth, pitting or blued surfaces, and check how far the cross shafts and thrust washers have worn. Excess backlash between side and pinion gears confirms the gear train is worn. Our spider gear failure symptoms guide walks through the inspection, and the Dana 80 problems and rebuild cost guide covers bearing and pinion wear you should check at the same time.
Yukon lists this kit for the Dana 80 Trac Lok with 35-spline axles. Dana 80 shafts come in 35 spline (1.50 in. diameter) and 37 spline (1.58 in.), so count your splines first; a 37-spline axle needs a different kit. Dana used the Power Lok in the Dana 80 until 1998, when the Trac Lok replaced it, so earlier trucks may have a Power Lok carrier. Some catalog data also lists this kit for the 35-spline Power Lok, but Yukon's own page names the Trac Lok only, so confirm your carrier type before ordering. It is not for Dura Grip carriers. Common Dana 80 trucks include the 1994-2002 Dodge Ram 3500 (and some 2500s with the diesel or V10 and a manual), 1999-2016 Ford F-350 dually and GM 1991-2002 C3500 HD. Send us your axle tag and VIN if you want a second check. More axle parts are in the hard parts collection.
Pull the axle shafts, remove the carrier, then take out the cross shafts and open the case following the service procedure for your carrier, keeping the clutch stack in order. Clean the case and check the bores where the cross shafts ride. Assemble with new gears and thrust washers, coat everything in gear oil, and reinstall. If the carrier bearings are noisy or pitted, the Dana 80 carrier bearing kit is the time-saver while the carrier is out, and a full Dana 80 master overhaul kit covers pinion bearings too on 98-up Fords. Yukon's setup chart lists Dana 80 bearing caps at 90 ft-lb and ring gear bolts at 175 ft-lb. Refill with the gear oil your owner guide calls for and add limited-slip friction modifier; our friction modifier guide covers how much. A Hardcore Dana 80 cover is a good upgrade on trucks that tow.
| Brand | Yukon Gear & Axle |
| Part number | YPKD80-P/L-35-R |
| Fits | Yukon Gear Trac Lok Positraction internals For Dana 80 and w/ 35 Spline Axles |
| Type | Ring & Pinions |
| 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.
No. It includes two side gears, four pinion gears, the cross pin shafts and the side gear thrust washers. The clutch discs and steel plates are separate, so inspect them and replace them if they are glazed or worn thin.
No. This kit is for 35-spline axles, which are 1.50 in. in diameter. The 37-spline shafts are 1.58 in. and need different side gears.
Maybe not. The factory Dana 80 limited-slip was a Power Lok until 1998, then the Trac Lok took over. Check the carrier before ordering, and send us your axle tag if you are unsure.
Yes. The Trac Lok uses clutch packs, so add limited-slip friction modifier unless your gear oil already contains it. Missing modifier is the most common cause of chatter in turns.
Not properly. The axle shafts come out first, and the carrier has to be removed to disassemble the case, clean it and check the cross shaft bores. Plan to inspect the carrier bearings while it is out.
