Wow, I've read the whole post. Please OP ignore anyone just bashing. It's getting quite old in these forums. I can build anything I try and doing gears every time sucks. It's tedious and just when you think you have everything going well, you have to take it all apart again. Few things:
Your preload is a bit high. The spec for Dana 30 is 12-15inlbs when new. Dana 44's are higher. I personally wouldn't tear it apart for 15 inch lbs but that's your call. I'd recheck them after break in. I did crush sleeve with my d30 and d44 when I initially did my gears and I did a CSE in the ProRock 44 I just built. For me CSE's don't gain you much. Pulling them on and off for changing shims is a pain. It's difficult to get to the shims and preload should be checked with the carrier installed with full preload once finished. The axles and tires don't change pinion running torque much but the preload on the carrier does especially before break in. Yes you definitely can precrush a sleeve for those mocking. When you use a setup tool as soon as the sleeve starts to crush the torque required to crush down to running torque becomes considerably less. It's no different precrushing in a press. For those that said run it down near the length required, bad idea an not necessary. Crush the sleeve in a press until it starts to move, then stop. Install and crush with the pinion bearing until running torque achieved. That's it.
The abs coming on is definitely not caused by the locker. Unless the front tires are chirping they are spinning free. The abs sensors are on the hubs and just check wheel speed. I damaged my abs sensor when changing my gears the first time with no visible damage to wire or sensor. Recheck the wires, unhook and reconnect the connectors, and pull them off the hubs to make sure nothing broke. It's very easy to snap them inside the hub. Recheck your steering wheel is absolutely straight at ride height with wheels straight. Finally replace them. I did fine with an aftermarket but OEM is always a good way to go.
Keep posting your symptoms and everything you've tried. Scan the codes (autozone will do it for free) and post up what you're seeing.
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D44 Yukon Zip Locker - 4.56
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