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The purpose of the crush sleeve is to set the pinion depth. The pinion depth being how far into the casing the pinion gear goes. If it goes too far the gear mesh is adversely affected. You cannot simply replace the crush sleeve and torque it to a standard spec and expect it to be at the correct depth. It doesnt really work like that. The crush sleeve is not a torque limiter. It is means of allowing the gear to sink into the carrier so that the proper gear depth is attained. My guess would be you have damaged either the ring gear or the pinion gear or both. Theres no easy fix here. If you want to get walked throught he process of setting up a rear end we can do that but it takes a few specialized tools you'd have to buy ( Theyre always nice to have ) for $120 or so. The gears may be damaged though and might need replacement. Gears CAN be destroyed in a city block if the pinion depth is off by a good bit. It sounds like it might have been. The exposed thread count might have been the same on the new and old yokes but you didnt take into account the depth of the yoke . a few 10's of thousandths of an inch off of the proper gear depth will destroy a gear set Pronto.
Your best bet is probably a replacement rear end unless you like learning new skills ...a lot .
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No truck :-(
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