I asked this question on another forum, but I really want your guys two cents...My '66 F250 has the stock Dana rear end with the 4.10 gears. I really want to change it out for the 3.54. Now, I understand that ratio is REALLY difficult to find, so my question is: what is a more feasible alternative? I heard changing gears in a Dana is difficult, so would finding a complete rear end be a better option? What rear ends/years are compatible for my 250?

 

You can buy the 3.54 ring and pinion for a Dana 60 at the link below. Since you run 4.10 now the carrier should be the same. Changing out gearsets does take a little experience with shimming for the proper backlash. Otherwise things can be noisy and start to wear prematurely.

High performance Yukon replacement Ring & Pinion gear set for Dana 60 in a 3.54 ratio - YG D60-354

 

Thanks for the link! That would be the best route. I just may see if i can find a good garage around town who has experience doing that kind of work...unless its a job I could do? Im an aggressively average wrench(:

 

If you only have the one to do I wouldn't got to the expense of tooling up for it and run the risk of still having to hire someone else to finish it out. I have done 3 Danas and decided the rear loaders are better left to the experts. Not particularly difficult but they can be very tedious and sometimes frustrating.
On the other hand if it is a skill you want to develope then be sure to read up on it well before you pull the differential apart. There's steps you need to follow that will greatly simplify the swap.

 

What tools do you need? I know you can do it without a case spreader.

 

My advice is dont be afraid of it. It takes less tools than a 9", but like anything of this nature like rogue40 said, they can be a bit of a pain in the a__ at times.

Do your homework, make an educated decision. If you think you can handle it, do it. If not, farm it out to a reputable pro.

 

I can be done without a case spreader but you're making it difficult. It is best rented if you can find one because they are stupid expensive for what you get.
Other expenses are dial a dial indicator and base, inch/pound torque wrench, a set of "setup" bearings, a press with bearing splitter, a set of centering bars if you start from scratch.
Of course you can do like a friend did with his. We ripped the carrier and pinion out, swapped the gears and stuffed it all back together with nothing even so technical as a torque wrench. Didn't change a single shim and crushed the sleeve with an impact wrench and drove that truck another 50,000 miles before a 988B backed over it at work one day.
Sometimes you get lucky, lol

 

Yeah, looking at the online installation instructions from Yukon, it looks pretty damn tedious and precise...

 

Truck I just bought has a Dana 3.54

Just did a gear set in a Dana 60 a week or so ago. A pain
You will need a shim kit which most parts stores do not have.
Prob have a shop set it up for you for less $$ than buying the shim-small parts kit.

Just so you are aware there are different spline counts for the Pinion yoke.
So if you order a gear set ask the spline count and compare with your yoke.

 

I checked with a reputable local shop and they quoted me $1200. Think I'll look for a used rear end!

 

HOLY SHIZNIT!

 

Shazbot!!

If a used rear proves difficult to find, maybe read this book and see if it helps. I've got it and it is on my short list of future reads.




Na-Nu Na-Nu...

 

Skip replacing the gears, it is not for the weekend garage monkey. Go to the boneyard. I think any rear ends up through a 72 will bolt in. If you are willing and have welding skills you can go later model like the one in mine out of an '81. You have to move the spring perches and shock mounts out roughly an 1 1/2". Parts are slightly easier to get for the later model and it had gargantuan drums.

 

Nuts pricing! Does that include a full rebuild or just changing out the gear set?

I just GAVE one away a week ago . . . The gear set can be had for around 200.00-350.00 depending on brand. Labor should not be more than a few hundred tops.

Summit Racing gear set for 189.00

http://www.summitracing.com/parts/mgr-d60-354/overview/

Find a Dodge or Chrysler tech or a Ford Tech to change gears for you. Thats as long as what you have is good other than gear change.

Should be able to do the job for 500.00 3.54 a much better daily driver gear set.

 

That book looks great! I'm gonna look for a rear end from a '67-72, but ****, maybe I can find a spare 4.10 and take my time swapping out gears to that one?
It would be fun to try...