I think I got my front diff pretty much nailed down. I realized that I needed to move my pinion down to get a good pattern and that even with only the factory shim, it was still a bit too high. So I took out the factory shim (.053") and added shims under the pinion bearing race, eventually ending up with .048", so bringing the pinion down .005" from factory. I got the resulting pattern, which looks solid:
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Then I went to put everything together for the final assembly and had the opportunity to get super pissed.
For anyone who doesn't know, you put the pinion assembly together with a crush sleeve between the two pinion bearings which is slowly crushed as you torque on the pinion flange. This then allows you to fine tune the preload of the bearings.
Everyone, including the mfg instructions, say you can do this with an impact wrench, breaker bar, or in tough cases, get everything started with a press.
I started with an impact gun and that did nothing, so I put it in my 12 ton press to get the sleeve started. That didn't budge. So, I moved on to use a breaker bar as indicated in the instructions.
AND THEN THE PINON NUT STRIPPED... GREAT. Luckily it seems that the threads on the pinion gear itself are usable, which I really hope is true, otherwise I'm out $200+ for another set.
Super frustrating though as I was following the instructions AND industry best practice. Now I need to wait for another nut in the mail and have to figure out how to get this thing on...
Rebuilding diffs is definitely a three banana job.