how to remove a crush sleeve??
is it ever, under any foreseeable circumstances, necessary to disassemble an axle assembly (i.e. remove the carrier assembly, axle shafts, and pinion gear) in order to remove a CRUSH SLEEVE for a pinion seal change?
Assuming that everything, save the pinion seal, was in its proper place and/or in proper working order.
if so, why?
Sorry. its a stock axle. Dana 35 rear axle on a 03 wrangler
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers.
(4) Mark propeller shaft and pinion yoke for
(5) Remove propeller shaft from the yoke.
(6) Rotate pinion gear three or four times.
(7) Record the rotating torque of the pinion gear
with an inch pound torque wrench.
(8) Hold the pinion yoke with Spanner Wrench
6958 and remove the pinion nut and washer.
(9) Remove pinion yoke with Remover C-452 and
Flange Wrench C-3281 (Fig. 31).
(10) Remove pinion seal with a suitable pry tool or
a slide hammer mounted screw.
(11) Remove front pinion bearing with a pair of
pick tools to pull the bearing off the pinion gear
shaft. If the bearing becomes bound on the shaft,
lightly tap the end of the pinion gear with a rawhide/
(12) Remove the collapsible spacer.
(1) Install new collapsible spacer on the pinion
(2) Install front pinion bearing.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 32).
(4) Install yoke with Installer W-162-D, Cup 8109
and Spanner Wrench 6958 (Fig. 33).
(5) Install the pinion washer and a new nut and
tighten the nut to 217 N·m (160 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. If preload torque
is exceeded, a new collapsible spacer must be
(6) Using yoke Spanner Wrench 6958 and a torque
wrench set at 353 N·m (260 ft. lbs.), slowly tighten the
nut (Fig. 34) in 6.8 N·m (5 ft. lbs.) increments until
Fig. 31 PINION YOKE REMOVER
1 - WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 32 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 33 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
TJ FRONT AXLE - 181FBI 3 - 33
rotating torque is achieved. Measure the rotating torque
with inch pound torque wrench frequently to avoid over
crushing the collapsible spacer (Fig. 35).
NOTE: If more than 353 N·m (260 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(7) Rotating torque should be the recorded reading
during removal, plus an additional 0.56 N·m (5 in.
(8) Install propeller shaft with reference marks
(9) Install brake rotors and calipers.
(10) Install wheel and tire assemblies.
(11) Lower vehicle.
however, my question was: is there any possible circumstance under which the differential/carrier must be removed in order to remove the Crush sleeve?
example: the crush sleeve is so compressed that is unable to slide out of the pinion housing. i.e. the crush sleeve flares out to the point where it is impossible to remove from the pinion shaft. hence, youd have to remove the pinion.
I just reread your original post, you do not have to remove the crush sleeve to replace a pinion seal. As to your question, not something I've ever seen, but I guess anything is possible.
this is why i ask:
I see, even by the book you do not have to remove the crush sleeve to replace the pinion. If the bearings in your rear diff were that bad, I would expect to see metal in the fluid, galling/pitting in hard face surface of bearings.
I am pretty versed on auto repair laws in California. Have you picked it up yet? If not they can not hold a vehicle for non payment here. Threaten to get the Bureau of automotive repair involved and go through with it if need be (1-800-952-5210). In this state you must give writen or verbal authorization for any work beyond the writen estimate. Do not pay more than the $50.00 quoted. Also ask him what the rolling torque was, so when you tear it back down to make sure everything is torqued correctly you can set it back up correctly.
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