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1990 Ford Ranger Dana 35 TTB CRUSHED Sleeve, please advise.


sharpesteye

New Member

Ham Radio Operator
Joined
Apr 20, 2024
Messages
3
City
Mesa, AZ
Vehicle Year
1990
Transmission
Manual
I was originally just needing to replace the pinion yoke, as one of the ears that held the u-joint caps on broke off. So I measured the preload on the bearings, an ok 7-8in/lbs. Worn but not too bad. I was planning to just put the torque right back where it was. But, in an attempt to remove the seal, I crushed the crush sleeve (note: don't use a gear puller to remove that seal). The shaft that leads to the drive line, or where I removed the pinion yoke from, (I'm not sure if it's technically the input or output?) is totally locked up. I feel stupid believe me, a 20 minute job now a 3-5 hour job.

I have found some good resources as to the layout of the diff and there's one three part YouTube video of someone removing it but it's not very detailed. I just need to replace the crush sleeve. I realize that I'm going to need to take the whole diff out, but in order to do that, it looks like I pretty much have to undo the front end entirely. I guess I am looking for what I can do to make this as easy as possible. The diff is fine, I just need to fix my mistake. Please let me know if there's a way to make this as painless as possible. If that's even possible at this point... are there any modifications I should make when I'm in as deep as I'm about to be?
 

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