Dana 30 pinion install issue

We're replacing the locker in a HP dana 30 from a mid 90s XJ and were having an issue with getting the preload right.

The pinion is marked at 2.250 which is to factory spec so we don't need any shims for the pinion depth. We started with 35 thousandths and when we tightened the pinion yoke nut to 160 ft lbs it warped the oil slinger so we must have something very wrong. Here's the pinion as we have it setup now the only thing not here is the oil seal.

Anyone have any advice or see anything were doing wrong? Unfortunately the FSM we have is for a 99 and the front axle is not a 99.



Thanks for any help!

Skorpyo

Did you make sure your races were driven in all the way, and you had a good pattern on your ring and pinion before setting up your preload? Did you set your bearings while cranking the pinion nut to 160 lbs by spinning the yoke and tapping on the end of the pinion with a hammer? Could just be you need to add more preload shims. Lube your bearings well before cranking down on them.

you don't need the outer oil slinger to set preload. install it after you get the preload right, along with the pinion seal.

2.250 is the master housing depth that the ring and pinion was cut for. it tells you nothing about how many shims to use.

Typically, the preload shim pack is in the .065"+ range.