The Dodge Challenger Message Board

Upgraded to the 8.75 rear end a while back. When we had it on the lift, we decided to replace the pinion seal even though it wasn't leaking.
Ever since, I've had a slight leak from the pinion seal. I'm getting ready to remove it again and replace it, but I was told I might want to also replace the crush sleeve as well.

Any thoughts?

Any time you undo that big nut on the end of the pinion, you should replace the crush sleeve and re-torque to achieve the correct bearing preload.

Having said that, I once re-used one and it was fine. But I did carefully check that I did have the preload needed by measuring the turning torque of the pinion as described in the workshop manual.

Carefully removed the nut and assembly, removed the seal and inspected the yoke assembly shaft. There were burrs on the surface- almost as if it had been in a vice. Weird.
Gently sanded the shaft until all the burrs were removed and the shaft was smooth, applied some permatex red around the interior of the new pinion seal and gently reinstalled the new seal- making sure it was flush and tight all around.
Reinstalled the yoke assembly (after checking to make sure everything was still tight) and it works like a charm.
Bone dry and quiet!