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Old September 3rd, 2012, 10:59 PM   #1
Sludge-n-Freek
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Default Dana 35 new R&P setup help needed! BAD!!!

Ok, first off I'm not an expert gear setter but I have done a few and have had real good success but this Dana 35 has me beating my head against the wall! Second this isn't my truck its a 97 TJ my cousin picked up a while back and I never took it apart but got the job dropped in my lap last minute.

Now heres the problem that I'm having so far and tell me what you think. I cant seem to get a good pinion starting piont because for some reason I can't get a new crush sleeve to "crush". If I look at an exploded view to see if there are missing parts I see pics both with and with out an oil slinger between the pinion gear and the bearing but yet the old one looks to only have a shim, its only as large as the base of the bearing race. Now since this ain't my first rodeo I think what space that shim/slinger is taking up isn't much so after dropping in the pinion and putting the required shims under the bearing race to give it its correct height and installing the rest including the crush sleeve and torquing it all down it wont crush the sleeve and leaves the pinion loose in the case.

If I try to do a setup without the crush sleeve and just preload the pinion bearings everything can work out with a good pattern and backlash and all looks great! pop out the ring and carrier to pull the pinion so I can install the sleeve and Wham! Sloppy pinion and all my patterns are blown out? WTF!!!

I spent 7 hours on this POS Saturday and had to call it a dead deal but I still have to try something to get it rolling so any clues to what might be going on?
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Old September 4th, 2012, 09:52 AM   #2
bdd1469
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Is there a fat washer between the yoke and pinin nut missing?
Correct shim behind big pinion bearing? Must be if you have a good pattern.
Are you running out of threads on the pinion before the sleeve crushes,or are you just unable to crush the sleeve with your tool of choice.
Can you set the old pinion next to the new one and see any difference in length beteeen the machined bearing surfaces and the threaded length.
You may try assembly with old crush sleeve to see if that helps.If it does you can put the new one in a press to get it close,and finish crushing when you reinstall it.
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Old September 7th, 2012, 06:18 PM   #3
Jeeperz Creeperz
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Quote:
Originally Posted by Sludge-n-Freek View Post
pop out the ring and carrier to pull the pinion so I can install the sleeve and Wham! Sloppy pinion and all my patterns are blown out? WTF!!!
It's going to be sloppy until the sleeve starts to collapse. It's job is to keep the bearings from being smashed into the races.

So is the problem that you can't crush the sleeve or that you ran out of threads?
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