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Dana 30 Crush Sleeve Assistance

C

chrisd01

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Original poster
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Mar 9, 2025
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Arkansas
Hello everyone. I'm in the process of regearing my TJ Dana 30 and I've got an issue with the crush sleeve. I'm getting my pinion preload value before actually hitting the crush sleeve. At first I thought I over torqued it so I disassembled everything and checked my crush sleeve height. It measures 1.405. My old one measured 1.355. I looked online and it looks like new ones range from 1.375 to 1.4. I reassembled and ran preload up to 30inlbs to verify I'm not hitting the crush sleeve and when I tore it back down, crush sleeve height unchanged. So, now I'm trying to figure out what my next move is. Thoughts and help are appreciated.

In case it matters, current pinion depth shims are 0.060.
 
Timken bearings and the crush sleeve that Revolution Gear sent.

Question, I did not reuse my oil slinger in case of needed to make lower pinion depth adjustments. Should I reinstall that and only out a .005 shim behind my race (slinger is .055). I've spent 30 mins trying to do that math in my head...lol.
 
Ryn9212000 said:
What was the issue with the slinger?
I’m having the same problem. I’m getting plenty of preload but very little torque on the pinion nut and I can’t find anything installed wrong.
Click to expand...

The issue with the slinger was he didn’t have it in there and so everything was tightening up before he had the nut tight enough.

D30s have their depth somewhere in the range of about 0.060-0.080. From the factory they use a 0.020” baffle and a custom thickness slinger. Combined, the two add up to around the big numbers I posted above. Mine was 0.020 and 0.054 I believe for a total of about 0.074.

The gear kits usually give one baffle, one slinger (not custom - usually 0.030) and you make up the remaining 0.010-0.030 with shims behind the inner race (added to the baffle stack).

I’d share how you currently have things stacked.
 
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First off, everything is new and carrier is shimmed and backlash set when I removed all the set up bearings and races installed the new ones when I got my preload on the pinion it happened with less then 20 ft-lbs of torque on the pinion nut before the crush sleeve began to crush.
It’s stacked : gear, slinger, bearing, race, shims, baffle, crush sleeve, race, bearing, spacer, oil seal, yoke.
I removed crush sleeve and have same results
I’m getting 17-20 preload with very little nut foot pounds.
 
Ryn9212000 said:
First off, everything is new and carrier is shimmed and backlash set when I removed all the set up bearings and races installed the new ones when I got my preload on the pinion it happened with less then 20 ft-lbs of torque on the pinion nut before the crush sleeve began to crush.
It’s stacked : gear, slinger, bearing, race, shims, baffle, crush sleeve, race, bearing, spacer, oil seal, yoke.
I removed crush sleeve and have same results
I’m getting 17-20 preload with very little nut foot pounds.
Click to expand...

Also carrier is not in when I’m trying to set pinion 🤙
 

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