It has been a really long time since I swapped gears in a D60 but... I am pretty sure a D60 DOES NOT use a crush sleeve. Item 5 are the shims that set pinion depth, item 7 are the shims that set bearing preload. The store probably gave you a crush sleeve for a sterling 10.25 it does use one.

Added: I found the instructions. If it is not too late read the More on setting pinion depth, it really helped me get pinion depth right the first time.
http://www.broncoii4x4.com/Dana60-Se...ar_setup-1.php
There is also a link there to DANAs assembly manual. It would be nice to have there special tools, but it lets you know how it should be assembled. Follow the post for the poor people method.

 

Ok, the truck is still apart. Can anyone please confirm if there is or isn't supposed to be a crush sleeve? I have to get this thing back together.

On another note, I never found the correct spindle seals for this project. Every one I bought was wrong. See this thread:

https://www.ford-trucks.com/forums/1...ndle-seal.html

The one I took out had metal around it, and a spring around the inside. All the ones I've bought are pure rubber and are too loose.

 

I've got my front D60 (from a '93 F350) apart right now. It does not have a crush sleeve. Item #7 are the shims that set the pinion bearing pre-load. Item #5 are the shims that set pinion depth.
Once the pinion depth is set, you change the pinion pre-load shims until it takes 20-40 inch-puonds of torque to turn the pinion, with the pinion nut torqued to 240-280 foot-pounds. After that, the carrier can go back in.

 

Thanks. Any tips on how to torque the pinion nut without spinning the pinion?

 

A big pipe wrench on the yoke, with a cheater bar works.
I sent you a PM with my phone if you want to call & talk...

Phy