Just had differential flange off of rear end to replace missing dust cover over differential seal. Although I marked nut with magic marker I believe I may have turned it one revolution too many thereby crushing the crush sleeve more than it was. Now rear end has a slight very slight noise to it that it did not have before. About 1000 miles ago all bearings in differential were replaced with Koyos. Can I just install and torque in a new crush sleeve w/o having to totally set up the differential again? Or shall I just drive it hoping it will wear in since I put new bearings in and hoping I don't burn up the new pinion bearings? Backlash is within tolerance. Most mechanics say drive it. Thanks in advance!

 

If you used an accurate torque wrench and torqued the pinion nut down properly, there shouldn't be an issue. If you over-torqued the pinion nut, then the bearing will be to tight, not allowing oil to lubricate and cool them, there will be problems...

 

rokblok, I think this did happen so can I just install a new crush sleeve and torque the nut to specs and all is well??

 

The torque specs with a crush sleeve are not fixed, but rather they depend on the rotational torque as measured when turning the pinion. If the preload is too much, you can't go back, you have to start over again with a new crush sleeve. Measure the preload torque you have on the pinion now. That will tell what you need to do.

 

If the preload is off, yes, you can install a new crush sleeve and torques to specs. It's not the best way to do it, since it's advisable to go through everything (backlash, preloads, etc), but I've seen it work fine.

Someone else may have a different experience though.