Yukon Dana 80 Rear Master Overhaul Kit- 4.125" Pinion Bearing
YUKYK D80-A
The Dana 80 Rear Master Overhaul Kit provides the bearings, races, seal, shims, and setup hardware needed for a complete Dana 80 rear differential rebuild. This version is specifically designed for housings using a 4.125" outer-diameter inner pinion bearing race and includes Timken bearing components for dependable service in heavy-duty truck, towing, commercial, and off-road applications.
Because Dana 80 axles were produced with multiple pinion bearing configurations, verifying the inner pinion bearing race size is critical before ordering. This kit uses the HM807046 / HM807010 inner pinion bearing set and includes the hardware and setup materials required to establish proper pinion preload, carrier preload, backlash, and ring-and-pinion contact pattern during assembly.
Includes:
- Carrier Bearings and Races
- Pinion Bearings and Races
- Pinion Seal
- Complete Shim Kit
- Ring Gear Bolts
- Pinion Nut
- Oil Baffles and Slingers
- Thread Locker
- Gear Marking Compound with Brush
- Silicone Sealant
Specifications
| Specification | Details |
|---|---|
| Product Type | Master Differential Overhaul Kit |
| Axle Application | Dana 80 Rear Differential |
| Position | Rear |
| Inner Pinion Bearing Race OD | 4.125" |
| Inner Pinion Bearing Set | HM807046 / HM807010 |
| Bearing Manufacturer | Timken |
| Axle Spline Compatibility | 35-Spline and 37-Spline Applications, Depending on Axle |
| Carrier Bearings and Races | Included |
| Pinion Bearings and Races | Included |
| Pinion Seal | Included |
| Shim Kit | Included |
| Ring Gear Bolts | Included |
| Pinion Nut | Included |
| Oil Baffles and Slingers | Included |
| Setup Materials | Thread Locker, Gear Marking Compound with Brush, and Silicone Sealant |
Fitment
| Make | Model | Year Range |
|---|---|---|
| Chevrolet | C3500 | 1992–2000 |
| Chevrolet | C3500HD | 1991–2002 |
| Chevrolet | G30 | 1992–1995 |
| Chevrolet | K3500 | 1990–1998 |
| Chevrolet | P30 | 1997–1999 |
| Dodge | B3500 | 1995–1998 |
| Dodge | Ram 2500 | 1994–2002 |
| Dodge | Ram 2500 Van | 1999–2003 |
| Dodge | Ram 3500 | 1994–2002 |
| Ford | E-350 Econoline | 1988–1998 |
| Ford | F-350 | 1988–1997 |
| Ford | F-Super Duty | 1990–1997 |
| GMC | C3500 | 1992–2000 |
| GMC | C3500HD | 2001–2002 |
| GMC | K3500 | 1992–2000 |
| GMC | P3500 | 1997–1999 |
Fitment Notes:
- Fits Dana 80 rear differential applications only.
- Designed specifically for housings using a 4.125" OD inner pinion bearing race.
- Uses HM807046 / HM807010 inner pinion bearing components.
- Compatible with 35-spline and 37-spline axle configurations depending on application.
- Vehicle year and model do not guarantee fitment because Dana 80 axles were produced with multiple bearing and housing configurations.
- Verify the actual axle model, inner pinion bearing race OD, spline count, and differential configuration before ordering.
- Axle swaps are common in heavy-duty and off-road builds, so identify the axle itself rather than relying only on the vehicle application.
- Professional differential setup is recommended because pinion depth, bearing preload, backlash, and gear contact pattern must be established accurately.
FAQ
How do I know which Dana 80 master overhaul kit I need?
The inner pinion bearing race size is one of the key identifiers. This kit is specifically for Dana 80 housings using a 4.125" outer-diameter inner pinion bearing race and the HM807046 / HM807010 bearing set.
What is included in a Dana 80 master overhaul kit?
This kit includes the carrier and pinion bearings and races, pinion seal, shims, ring gear bolts, pinion nut, oil baffles and slingers, thread locker, gear marking compound, and silicone sealant needed for a complete differential rebuild and setup.
Will this kit fit both 35-spline and 37-spline Dana 80 axles?
It can be compatible with both 35-spline and 37-spline Dana 80 applications, but spline count alone does not determine kit fitment. The housing and pinion bearing configuration must also match.
Why does the inner pinion bearing size matter on a Dana 80?
Dana 80 axles use more than one pinion bearing configuration. The inner race must match the machined bore in the housing, so installing the wrong bearing set can prevent proper assembly and pinion support.
Do I need a master overhaul kit when installing new Dana 80 gears?
A complete overhaul kit is recommended when changing gears or rebuilding a high-mileage axle because accurate pinion preload, carrier preload, backlash, and tooth contact depend on fresh bearings and correct setup hardware.
