Apologies for attempting to revive a post that’s been dead for nearly 6 months, but this is the closest thing I’ve found online to the issues/questions I’ve run into.
I am rebuilding the front Dana 30 out of my elderly father’s ’98 TJ. The inner pinion bearing was essentially gone, had been ingested by the differential, leaving behind nothing but metal “paste” and some of the rollers. This is the first time I’ve been inside a differential, so this is a big time learning experience for me.
In any case, this is a low pinion Dana 30 so it does use a crush sleeve.
Is the orientation of the crush sleeve shown in post #12 of this thread correct? Narrower side toward the nut? Larger side toward the inner bearing? It’s unfortunately not something I paid attention to when removing what was left of the pinion.
Additionally, the Yukon Gear rebuild kit I purchased came with 2 oil baffles (I’m assuming one was an extra). I don’t mean the oil slingers, this is something else. The baffle is supposed to sit between the pinion inner bearing race and the housing, along with any shims needed to set the pinion height. Due to the damaged components inside this differential when I disassembled it, I cannot say for sure if it previously had this baffle or not. I found no remnants of it, but I’m not sure how it couldn’t have been there. The diff had never been opened since new. In any case, with the baffle in place, the crush sleeve will contact with it and deform it on its way to the inner bearing, which doesn’t seem right. Neither end of the crush sleeve is small enough to pass through the hole in the baffle, though the narrower end is close. Does any of this make sense to anyone and do you have any idea what I’m supposed to be doing here?
Many thanks in advance for any replies.
