Yukon Gear Master Overhaul Kit For Dana Super 60 Diff

Yukon Gear Complete Differential Rebuild Kit for the Dana Super 60

The YK D60-SUP Yukon Gear Master Overhaul Kit contains every component required to perform a complete rebuild of the Dana Super 60 differential. Built around industry-leading Timken bearings and precision-engineered seals, this kit delivers the accuracy and durability that professional rebuilders and serious off-road enthusiasts depend on. Yukon Gear engineers have tailored this kit specifically for this application, ensuring that every part arrives ready for installation without modifications or substitutions.

Features and Benefits

• Timken Bearings and Races - Both carrier and pinion bearing sets sourced from Timken for precise load-handling and long service life
• Complete Shim Set - Full range of shims for accurate pinion depth and carrier bearing preload setup on the first attempt
• High-Quality Pinion Seal - Engineered to prevent fluid contamination and leaks under extreme load and temperature cycles
• Ring Gear Bolts and Pinion Nut - Grade-correct fasteners included so nothing is left to chance during assembly
• Crush Sleeve - Correct crush sleeve for proper pinion bearing preload in this application
• Thread Locker and Marking Compound - Setup consumables included so the technician can verify gear contact pattern and secure fasteners
• Application-Specific Engineering - Yukon conducts extensive research to ensure all parts match exact tolerances for the Dana Super 60
• One-Year Limited Warranty - Backed against manufacturer defects for twelve months from the date of purchase

Vehicle Fitment

Product Specifications

What Is Included

The YK D60-SUP kit includes all components listed below for a complete differential overhaul.

• Timken carrier bearings with races (inner and outer)
• Timken pinion bearings with races (inner and outer)
• Pinion seal
• Complete shim kit (carrier and pinion depth shims)
• Ring gear bolts (full set)
• Pinion nut
• Crush sleeve
• Oil baffles and slingers where applicable
• Thread-locking compound
• Marking compound with application brush
• Cover gasket

Frequently Asked Questions

• Q: Does installing this kit void my vehicle warranty?
  A: Under the Magnuson-Moss Warranty Act, a manufacturer cannot void your vehicle warranty simply because you installed an aftermarket part. They must demonstrate that the aftermarket part caused the specific failure. High-quality components like those found in YK D60-SUP protect your drivetrain investment.
• Q: Does this kit include a crush sleeve?
  A: Yes. A crush sleeve engineered for the Dana Super 60 differential is included, so you can achieve proper pinion bearing preload without sourcing additional parts.
• Q: What special tools are required to complete this rebuild?
  A: You will need a pinion bearing press and puller set, a torque wrench capable of at least 200 ft-lbs, an inch-pound torque wrench for preload measurement, a bearing race driver set, a dial indicator with magnetic base for backlash measurement, and a gear marking compound brush. The marking compound and thread locker are included in this kit.
• Q: Are Timken bearings better than standard replacement bearings?
  A: Timken is an industry leader in tapered roller bearing manufacturing. Their bearings exceed OEM specifications for radial and axial load capacity, making them the preferred choice for differential rebuilds under heavy-duty or off-road use.
• Q: Will this kit work with aftermarket ring and pinion gears?
  A: Yes. The shim set covers the full adjustment range needed whether you are reinstalling factory gears or fitting a new aftermarket gear ratio.
• Q: How do I verify gear contact pattern with this kit?
  A: Apply the included marking compound to the ring gear teeth, rotate the pinion under load, and read the contact pattern on the gear face. Adjust the included pinion depth shims until the pattern is centered on the drive face for optimal load distribution.
• Q: What does the one-year warranty on YK D60-SUP cover?
  A: Yukon Gear covers defects in materials and workmanship for twelve months from the date of original purchase. Normal wear, improper installation, and damage from abuse are not covered.
• Q: Can a home mechanic install this kit?
  A: Differential rebuilds require specialized tools and knowledge of gear lash, bearing preload, and contact pattern analysis. An experienced home mechanic with the proper tools can complete this job, but professional installation is recommended to ensure correct setup and protect your drivetrain.

Installation Overview

Follow these steps to install the YK D60-SUP master overhaul kit components.

1. Lift the vehicle safely and drain the differential fluid completely.
2. Remove the axle shafts, then unbolt and remove the differential cover.
3. Mark the bearing caps and remove the carrier assembly, noting shim locations before disassembly.
4. Drive out the pinion using a press or soft hammer, removing the old bearings, races, and seal.
5. Press in the new Timken pinion bearing races using a race driver set.
6. Press the new inner Timken pinion bearing onto the pinion shaft, then install the new crush sleeve.
7. Install the pinion into the housing, install the outer pinion bearing, and torque the pinion nut to specification while monitoring rotating torque until the correct preload is achieved.
8. Install new carrier bearings onto the carrier. Install the carrier with the original shim stack and verify backlash with a dial indicator.
9. Apply marking compound and check the gear contact pattern. Adjust shims as needed to center the pattern on the drive face.
10. Install the ring gear bolts with thread locker and torque to specification.
11. Install the new pinion seal. Reinstall the carrier bearing caps to specification.
12. Clean the cover flange, apply the included gasket, and reinstall the cover.
13. Reinstall axle shafts, fill with the correct gear oil to the fill plug level, and road-test the vehicle.

WARNING: This product can expose you to chemicals including lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.p65warnings.ca.gov.