I now suspect the wheel bearings where serviced at least one more time since Dealer records at 90K indicated. I say this because both front rotors have been replaced, as I found the tell-tell hammer marks to break loose on axle hub from rotor, additionally rotors are 32MM thick.
Wheel bearing also looked good with zero pitting on bearings, I've not seen that before. Claw washer was scored on more on one side then other, which is common of loose wheel bearing. So I flipped them good side in. Snap Ring (SR) gap was a bit to wide, hub flange & axle teeth were passable (minimal wear). All in all the best I've seen in some time, but over due for service as i suspected. I set breakaway (BW) preload at 12.5lb both sides, and was able to get DS hub flange to SR gap down to 0.15mm with a new 2.4mm SR, PS gap down to >0.04 with a 2.6mm SR. Hub flange were still serviceable, so I keep them.
Edited:
It took 72ft-lbf torque on adjusting nut of PS wheel bearing to get 12.5 BW preload. The FSM doesn't give a maximum torque here. But I become concern when I go much over the 47ft-lbf FSM states for locking nut. So when I need a high torque much over 50 or 60ft-lbf on adjusting nut, I schedule bearings for replacement on next service in 30K miles.
You'll see later in thread, the decision was made to replace wheel bearings & races now.
Page # 8 post #147
So install begins:
I really like that marine grease as in holds in, makes next service a snap. It also protects my parts from rust and reduce water entry.
All ready for snap ring.
Notice the can of degreaser (DX330) great stuff for prepping paint. I also use on rotor before brake pads touch them and axle hub flange studs before blue lock-tight and torque nuts to 24ft-lbf.
I finished up yesterday once I was able to get the last 2.6mm snap ring in the state of Colorado.
Once I installed it and measured snap ring to hub flange gaps with my "puller set-up" on to insure very tight & true reading, I torqued on the calipers bolts to 90ft-lbf, brake line braket 24ft-lbf, speed sensor wire to 9ft-lbf & speed sensor to 71in-lbf on. Then mounted wheels & tires, replacing those PITA wheel locks with standard lugs torqued to 97ft-lbf.
Stock photo from my 01.