Just wanted to make sure no other posting was made on this subject: So here I go. I have an 81 d150 360, auto and a 9.25 diff. It came with 2:71 gears and was not enough for my 5th wheel. I found a set of 3:55's crown and pinion(used) but in extremely nice shape, and proceeded to rebuild the diffy. I found as much info as I could on doing this rebuild and made sure that the tooth pattern was correct for pinion placement (shimming) as well as getting the backlash set (adjusters) with the side bearings. What is the proper way of setting the crush sleeve so as to get the proper preload on the pinion bearings? Every thing I put into this job is brand new except for the crown and pinion, I made sure that everything went back into their original positions. The chrysler manual calls for 200 ft/lbs of torque for setting the preload. I have the proper wrench for holding the yoke while using a 3/4" drive torque wrench for achieving the torque value in the manual. The initial drive after putting everything back together is just a simple drive down the block under very little throttle pressure, no hard launching, and sure enough noise coming from the rear. The test I do for this noise is; on and off the throttle and not hard launching either, noise on the get go and none on letting off. My drive shaft is a two piece and has new u-joints as well as a new steady bearing. The sip sleeve is well greased. I have tried two rebuilds now and same thing. And yes I have used new crush sleeves and bearings for each job. Now I'm to the point if it blows up it blows up. So far it hasn't let go. I would really like to do this job again, but obviously I'm missing something here, or have overlooked something crucial. The camper has been parked permanently and the truck rarely sees the road. Any advice or leads on this topic would be greatly appreciated [>:] Thanks Royce.

 

If you are getting diff noise on coasting you need to check your rear pinion bearing, sould be the smaller one. If thats not it check your back lash again on the coast side of the ring gear, best way to do it is with a special paint to mark the contact points.