Having trouble with Dana 30 crush sleeve

[DainBramaged]

Hey everyone:

I am trying to install a new pinion in my Dana 30 front axle.
For some reason, I am not able to crush the sleeve to set the bearing preload.
I did this on my 8.8 rear with no problems but this one is just not working.

I tried a breaker bar. I tried using the handle from my jack. I went out and bought a DeWalt electric impact rated to 340 ft lbs.
The sleeve is supposed to crush at 160 ft lbs. The impact destroys the nut but the sleeve does not budge. I have
gone through 4 different nuts. I replaced the crush sleeve. Nothing has made a difference.

Take a look at how much I deformed the washer between the pinion nut and yoke. That is not supposed to happen.

I do not believe this is a lack of force.
Something else is going on.

Any ideas?

Thanks
Neil

[Greg]

Looks like you may have crushed it already, it is a fine line between preload and contact. Make sure it is the right crush sleeve too.

[DainBramaged]

The pinion assembly is still loose in the housing. I can wiggle it up and down. If the sleeve is crushed, the bearings should hold the pinion fixed in place.
I am pretty sure I have the correct sleeve. I got it from 4 wheel parts. Nothing else in their catalog has the same shape.
Here is a pic of the crush sleeve I have:

[Greg]

The thing I am wondering and I am sure it is just a miscommunication but, you say you are changing your Pinion? You can't just change your Pinion, do you mean you are changing the bearing? or your gears?

[DainBramaged]

I am changing the ring and pinion. Right now I am working on installing the pinion, setting the bearing preload.

[Greg]

Something is incorrect but I am out of simple things to check. I have only done five Dana 30 crush sleeves and two were failures. All you can do is verify correct parts, correct orientation, have a spare or two and be patient. It takes quite a bit of torque to start the crush but, it should not be deforming washers.

[DainBramaged]

it should not be deforming washers.

That is my point exactly.

I think I will try using a press to crush the sleeve down to the right size instead of relying on the nut and threads to do it.

[DainBramaged]

I took the axle to mmmmbeer. We crushed the sleeve with his press. That solved it.

Thank you for everyone's help!

[MudMan]