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Re: Little rear end help please (Dana 60)
IIRC the case ratio split on a D60 is 4.10 down and 4.56 up. So a set of 3.54 gears should work on the 4.10 posi case. The bearings should be swappable too if you can pull them and keep the servicable. However the rear will still need to have the gears reset and reshimmed as required. If you don't have these try to download a copy of Dana's servcie booklet #5309-3 and #X510-8DSD.
If it were me I'd drive the truck a lot with the 3.54 and make sure you like them with a normal load on the truck first. Then you can decide if you want to keep the 3.4 or go with the 4.11s during the posi installation. However I am not a big fan of used gears in a different housing.
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