I'm in the process of installing 4.56 gears in my 99 ram 1500. Its the 9.25 differential. Upon installing the pinion gear and tightening the nut the pinion tightens up before it begins crushing the crush sleeve. Usually there's some forward and back movement in the pinion gear before the sleeve crushes down but there's no movement.

 

Is pinion depth correct?

 

Yes. I made a setup bearing and did multiple setups to achieve the best contact pattern I could. Now that I have that I pressed the new bearing on and installed the crush sleeve and here I am having problems lol

 

May wanna look at the crush sleeve eliminator kits.

 

I can do that. How does that work then? Would I just torque the nut to the 210ftlbs and have that setup to be the 25inlbs rotating torque? I understand I have to use the sleeve and shims to achieve that.

 

Otherwise could I put a small spacer or shims behind the crush sleeve to take up the gap before the crush sleeve?

 

Think I would just go with the eliminator. Not sure how friendly shims would be with the pressure you put on a crush sleeve. Check 'em out, fair few folks sell 'em. Much better option methinks.

 

I ordered one up so I guess I'm dead in the water till that shows up.

 

Have you compared the old vs. new crush sleeve to see that it's the correct length? You're sure you are uaing the new crush sleeve and not the old one?

 

Yes. I checked that all out cause that would be an easy mistake to make, but I had the new crush sleeve in there. I've set up a few GM rear ends before and the pinion install is nearly identical to the Chrysler 9.25. Every time I've done a GM there was about 1/8-3/16 of an inch when the nut tightened up before the crush sleeve crushed. That just isn't the case here so I'm not sure what's going on. The new pinion did need more shims than the old one to get a fair contact pattern but even at that it's less than 1/32 of an inch.