[mmsafd]

2000 Excursion 4x4. Is it necessary to replace the crush sleeve every time you replace the rear pinion seal? I had my pinion seal replaced 12 months ago at the dealer, now the rear end is making noise. I took it to the dealer because I was in a wheelchair at the time and from what I know the crush sleeve is critical. So I figured it would be done correctly. From what I know if you do not replace the crush sleeve it will mess up the back lash and cause the gears to wear out. They are telling me $2300 to put a ring and pinion in it. They are saying that it is not necessary to replace the crush sleeve. They say the gears are trashed. Oh and this is without removing the diff cover to do a visual inspection. I looked at the truck myself on the lift.

 

[RT]

Run, Forrest, Run!

Find yourself a differential shop. Technically, according to Ford, the crush sleeve HAS to be replace every time. According to Ford, so does the pinion nut. I've seen a lot of guys re-use both of those parts without any damage, but it isn't the "correct" way to do the procedure.

You need a visual inspection. You need to get someone who does nothing but axles to do this. You'll find it will be considerably cheaper this way. You might consider getting the parts yourself and having them installed. PM Just Diffs or go to their website - JustDifferentials.com

There is an aftermarket spacer that replaces the crush sleeve. If I ever have to do my pinion bearings, that is what I'm going to install. That way, I'll never have to go through the crush sleeve process again if I have to replace the seal. Here is an example - Ford Solid Pinion Bearing Spacer

 

[mmsafd]

Thank you for the info. I called 4 other shops today. They also said the crush sleeve must always be replaced. Or the result will be a bad wear pattern setting in and destroying the gears.

Does anyone have documentation from a Ford source that states the crush sleeve should be replaced when removing the nut, yoke or pinion seal?

I am waiting to hear back from the dealer.

 

[ford_doctor]

Improper tightening of the pinion and not properly setting the preload on the pinion bearings will cause them to fail... and make noise. It is usually because the pinion bearing preload is too tight. The gearset will only be affected if the pinion bearings wear enough to cause the pinion to become loose. My suspicion is that whomever replaced your seal did not do it correctly and caused your current failure - I have seen this play out many times over the years. For me, I replace the collar.

However, I also work on a few Dodges at my dealer and I just replaced a pinion seal on a 9" front drive axle and followed the WSM instructions. In this case I popped the axles, measured the preload. Upon assembly, the collapsible spacer is reused and the pinion nut is retightened to the preload measured before disassemble PLUS 5 lb/in similar to how a Dana 50/60 or a Ford 10.5" rear is done on Ford front drive axles. It seems to me that anyone that wants to reuse a collapsible spacer is either cutting corners to save time OR does not have the tools needed to set the pinion bearing preload. It is too easy to over tighten the pinion nut and you cant just back off the nut.

 

[mmsafd]

Ford Doctor. Thank you for all the info. I see that you are a Ford tech. Do you by chance have any documentation from Ford that says they should have replaced the crush sleeve? The service manager is telling me that Ford does not require them to replace it. Only on 1/2 ton trucks.

 

[Transdoc]

Never had to change a crush sleeve yet when just changing the seal. Most of the time the front pinion bearing is going and that's were you get the noise from and that's what takes out your seal(metal particles). The only time we change a crush sleeve is when we put a bearing kit in it(it comes in the kit). If you have never done this before please take it to a transmission shop or you can wipe out your bearings.

 

[ford_doctor]

Ford Doctor. Thank you for all the info. I see that you are a Ford tech. Do you by chance have any documentation from Ford that says they should have replaced the crush sleeve? The service manager is telling me that Ford does not require them to replace it. Only on 1/2 ton trucks.

The Service Manager is correct. If you are only replacing the pinion seal or pinion flange it is only stated in the WSM to replace a crush collar if the preload is exceeds specification during reassembly because simply backing off the nut will not correct the excessive preload. In that case a new spacer and pinion nut is required. As I stated, FOR ME it makes sense to replace the spacer and reset the preload because it is too easy to over tighten and cause damage to the bearings. If however new pinion bearings or a new gear set is being installed then a new collapsible spacer is required.

 

[mmsafd]

Thank you for the info. What is WSM?

 

[RT]

Work shop manual. I went back and looked it up and Ford doctor is right- has to be replaced if you go over at all. I stand by my recommendation to abandon the crush sleeve. You can buy the gears for less than $400. All new bearings add about 200. A good shop should do the install and have you out for less than half of what you were quoted.


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