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I'm redoing it as well. I got it set today and it's notchy. The only thing I can think of is the outer bearing was damaged when I drove the pinion back out of the case.
New bearings are on order, I have a spare sleeve and nut, there is a new seal in stock at the parts store. This job has gotten to the point of "throw money at it to make it go away".
I received my new yokes from Bair's, I need to get the ends ground to increase the clearance. That's next week, I have time to take another stab at the pinion setting.
The sensible thing to do would be to install the carrier and check the pattern before I remove the pinion. I'm reusing my old gears but I'd like to verify the pattern.
The Bair's reman yokes tested @ 50-55 for hardness with files.
I got the ends milled today for clearance, had a brief moment of doubt about my posi tune so emailed Gary again, and got things going together after he confirmed that my tune was good.
The differential is back in the car and the tires are back on the ground. All I have left to do tomorrow is tighten some suspension hardware and attempt to adjust the rear camber. It needed new strut rods, the old ones were bent and very loose.
That rear spring fought going back in, as did the strut rod bracket. Some creative jacking and colorful language persuaded everything to go back where it belonged.
I realized in the middle of that that my bottle jack and floor jack both leak down. They are both approximately 17 year old Craftsman.
Yes - BTDT!
You need the weight of the car on all the suspension bushings when you torque them down - or you will tear the rubber quickly when driven.
The diff is even more important - you can crack the ears if not done correctly.
It is rather easy to screw some cribbing together out of 4x4 lumber.4 levels of this will raise tha car 16 inches!
A little creativity is required to raise the car one level at a time.
I'll see if I can find a pic.
Got a short test drive, the noise that led me into checking the u-joints and differential is gone.
There was a new, interesting noise from the rear of the car. Under 25 mph is sounded like something rubbing, as I slow to a stop the noise turns to a squeak on the last couple of revolutions.
After a short run on the highway to listen to the bearings the noise was gone. I assume something self clearanced itself.
I'll roll back under it tomorrow and check everything out.
