Question on assembling the rear output shaft with 5-9 inch pounds rotating torque- is this done with just the bare output assembly before being installed in the case without the seal? Seems like a big difference between end play and this torque value. I have 0 play now but not near 5-9 inch pounds.
Correct just the output housing not installed in the t case..I'd start with all the shims installed and tighten down until you feel it bottom out or until no free play ..with no freeplay it should take about an 1/8 turn to achieve close to the preload your looking for .
when I did the HD shaft kit on my last one I was slightly tight with all the shims installed Wildhorses sent me another shim set again great customer service..