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Steve,
I'm glad to hear you've had 2 successes but I'd still be nervous about tightening the nut "to the correct torque". My (limited) understanding is that the bottom line objective is to have the correct bearing pre-load. I don't think this can be measured directly, but will result in a slight drag on the pinion flange when turning by hand. I've read/heard that this pre-load turning drag should take about 1.5 to 2.0 ft lbs of torque to overcome.
At some point (guessing here) it was found that XXX ft pounds on the nut would crush a new "pre-load sleeve" to length "Y", resulting in a bearing load causing "x" ft lbs to rotate the pinion flange.
My concern about using "XXX" ft pounds on the same (crushed) sleeve again, is that the sleeve will be crushed even more — and thus do too much of what was just right for bearing load the first time, (I'm also guessing that much/most of the initial XXX ft lb of torque went toward crushing the sleeve. But that's another guess.)
Anyway, I've only done one pinion seal (still OK after 100k miles), but I used the method that swede4 outlines below — marking and counting so the nut goes back exactly where it was when the crush sleeve was first installed.
Still wondering (and still looking for those motor mounts),
Bruce
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Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.
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