white trash i would disagree that the pinion crush sleeve can be set with the carrier in place. The pinion nut tread friction as well as variances in the crush sleeve prevent preload from accuratly being set by torqing the nut to XX ft/lbs or Nm. To do it correctly the carrier MUST be removed.
I wont disagee that the crush sleeve may be the source of the problem, how ever open diffs would not lend the truck to get into areas where the pinion flange could be struck by something in such a manner that it would further crush the sleeve.
RS
