. An analytical method of overlay design has some advantages such as to take into account the variation of loading types which will give more exact and accurate results. The purpose of this research is to analyze the pavement structure of Jakarta-Cikampek toll road,for analysis period between 1990-1999 and to calculate the residual life and overlay thickness required, based on the deflection data using FWD equipment and analyzed by ELMOD computer program.The results then were compared with the empirical method i.e. Bina Marga method. The result of Bina Marga method show that for Jakarta-Cikampek direction there were eight critical points which have residual life less than one year and 7,0 cm overlay thickness required. For Cikampek-Jakarta direction, there was no critical point, their residual life was more than 10 years, and overlay thickness required is 3,0 cm. The ELMOD program gives the result for Jakarta-Cikampek direction that there are two critical points which have zero residual life and one critical point which has residual life less than one year, the overlay thickness required was 7,2 cm. For Cikampek-Jakarta direction, there was no critical point, the residual life was more than 20 years and no overlay required.