Hey guys I had my BW 9bolt fail on me this spring and after finaly getting a new set of ring and pinion I am having trouble getting it to fit back into the carrier.

The pinion does not fit in the housing lol.

with a new inner bearing and race I slip the pinion into the housing, instal the outer bearing race, then the crush sleep and outer bearing, slip the yoke onto the pinion and that is where im stuck, the yoke bottoms out on the splines well before the yoke contacts the bearing.

The only way I can get any preload is when I slipped the old crush sleeve on before the yoke as a spacer.

My next issue is, even with the yoke bottomed on the splines, it still does not sit far enough in the seal to hold oil in. I need about another 3/8" further into the seal for it to seal properly.

I have tried reinstalled the old pinion and I get the same problems.

What happened??

 

First some questions... are the ring and pinion for 9-bolt and do you have the correct carrier????

 

Yea I even compared the new pinion to the old pinion and they are exactly the same. Now, not even the original pinion will fit in the carrier!

I explained my situation to a local drivetrain specialist and he is stumped. I scoured the carrier for any signs of damage that would cause this to happen.
He suggested that I might have the wrong yoke yet its the same yoke that came off the car

 

Check your pinion bearing. There were 2 different sizes the smaller one is pre 87 (I think) and the larger one later on. If you need the smaller one but installed the larger one the pinion will sit higher in the housing and therefore the carrier won't sit all the way down.