Okay,
So the dog is freaking about a new crate? And not being in the kennel, I got this right so far? (forgive me I'm slow)
So now we have this new identity in the house the dog doesn't want anything to do with, so far so good?

Where does the dog usually sleep?

 Quote: randy allen

Okay,
So the dog is freaking about a new crate? And not being in the kennel, I got this right so far? (forgive me I'm slow)
So now we have this new identity in the house the dog doesn't want anything to do with, so far so good?

Where does the dog usually sleep?

Maybe I am slow too, but I have re-read this thread now three times and am not 100% sure of what we're talking about. "My 2 year old Golden is terrified of her kennel! She was crate trained as a puppy and I think I made a mistake when we took the crate out of the house after she was able to be left out while we were away. She never really liked being in the kennel and never went into it unless we put her in. .... We're moving back to the states from japan in a few months so we bought a new travel kennel for her. "

These aren't interchangeable terms for me, so if the O.P. could just confirm what we mean .... "She was crate-trained as a puppy" .... meaning the same type of crate that we are now talking about for travel, right? I don't think it's a matter of semantics as much as it is clarity, because I'm trying to confirm that the crate she was trained in as a puppy (but never really liked) is the same crate that she is now terrified about. No new item .... but a ratcheting up of what was moderate dislike and is now terror. Is this accurate?

PS

It doesn't matter which term we're using .... what I am trying to get pinned down is whether the item that caused moderate dislike as a pup is the same item that is now causing terror.

Sorry for the confusion! I meant one of the plastic airline approved kennel. I'm not sure the difference between a crate and a kennel (I normally call a kennel the plastic ones and a crate the wire ones.)
She has never liked being in either. We had a wire one when she was a puppy and we got a plastic one to take on the plane. She's freaked out in both.
We took the top off the kennel and my 4 year old went in to it and Hana jumped right in with him. she was laying in there for a while with my son. With the top off, I put her food in and stood on the back side of the kennel (outside of it) and she went in to eat. Next step is going to put the top on but not the door.
She's always had really sensitive ears, doesn't like planes flying low over the house, guns, loud trucks, construction noies (we live on a military instilllation). I think she doesn't like the noise of her nails on the plastic. I have a big blanket on the floor of the kennel but she connects the kennel with that loud noise from when she was a puppy.
Thanks for all the help!

PS... She sleeps on a big pillowe on the floor in out bedroom. She hasn't been inside a crate or kennel in over 2 years! Even when we're gone she's able to roam the whole house. She is normally laying on the front mat or her one of her pillows when we get home.

Put her pillow in there before the top goes back on.
And leave it there when you put the rig back together.
If the pillow is too big, take the cover off and use that in the crate.

All other pillows are gathered up and put away.
The crate goes into your bedroom where she normally sleeps.

Perhaps she'll feel better with her blankie to keep her company.

Personally, I would not rush putting the top back on. You are having success with it off, so REINFORCE the successful things before going back to square one. If you put her pillow in there, I'd keep the top off for a while... You have a few months to work on this so there is no need to rush it.

You might even get creative... Instead of putting the top back on as the next step, maybe make your son a "fort" by putting a blanket over top of the crate (supported by two chairs) so it isn't dark and enclosed yet... let them play in their together.

When you do put the top back on, I'd have your son go in there, if he can fit!