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pinion seal and correct pre load..... i give up

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ok friends I started a thread asking about the proper specs for the pre load on my pinion seal...... a few members helped me out greatly but now i am getting a pop or a snap at the input shaft when the truck is shifted from forward to reverse or opposite..... if I take off slowly forward it makes no pop how ever if I shift to reverse and give a little throttle it pops..... that said I can set the parking break and shift from drive to reverse or back and forth and give enough throttle to put the drive train under actual tension I get this pop:nono:.......
here is my exact procedure
1. jack up removed calipers and cradles
2. removed drive shaft replaced all u joints carrier and cleaned slip yoke and re lubed with the special ford stuff ( white)
3. removed axle shafts
4. took inch pound reading ( bought torque wrench just for this) the reading was 14/15 inch pounds with about 16/17 inch pounds to break away
5. removed pinion flange nut ( every other truck I ever did this nut was so tight that it nearly broke a break over to get it loose... however this time it didn't even need a cheater pipe just a standard 1/2 inch ratchet)
6. used flange puller to remove flange
7. pryed out old seal
8. looked for crush sleeve didn't see one I assume it is behind the bearing
9. installed new seal and flange and new nut ( slowly tightening it while rotating and checking for inch pound resistance at least 4 times
10. eventually got to 17/18 inch pounds NOW I THINK HERE IS WHERE I WENT WRONG ...... IT NOW TAKES ABOUT 28/30 INCH POUNDS TO BREAK AWAY THEN GOES RIGHT BACK TO 17/18 INCH POUNDS.....

I have done many pinion seals on my other trucks(half tons) and never ever went to this great of detail just marked it old school counted the number of turns and lined up the marks and drove on down the road

either I have over cautiously not tightened it enough and there is slack or I have over tightened it and possibly screwed up something...... starting to think I should have just lived with the leak and the mess
I did this repair my self because I want to be the only one to blame when it is done wrong ( like now)

what are your opinions I am at a loss

I have heard so many different opinions on how to do this correctly and I have never heard the same story twice

they range from the redneck " just get er real tight and your good"
to the extreme of buying a inch pound torque wrench ( witch I have done)

about to give up and admit defeat take it to the stealership spend some money and probably end up with a un related problem

all your opinions would be very useful to me thanks

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