You often hear people say, I set it ( the backlash) up extra tight so it won't open up under load.
Bad misconception.
Back lash is spec'd as it is for a reason.
What you really want "extra tight" is the endplay or carrier preload.
In most Dana rears, that preload is supposed to be "minus" 10-15 thousands.
IOW - ZERO endplay, then 10-15 thousands preload. (more shims)
In order to get that, it is recommended to use a case spreader. So the assy will JUST go in snug with the case spread about 15 thousands.
I have a case spreader, but to be honest, I don't use it all the time.
Mostly when installing ARBs and rears like D35s with the shims on the outside of the bearings.
Once you get the feel for it, .0010 preload is just about what you can force in....
...On the bench. With the carrier dead square going in.
Laying on your back pressing the carrier up into the housing you aren't going to get that much force. And a 2 lb deadblow won't do it either. I have about a 5 lb plastic face DB. And feel like it is just barely enough on the bench.
One more thing to keep in mind. When you pulled it out. It was with used - broken in - bearings. That is even looser than it should be with new bearings.
So you REALLY should be going in TIGHTER than it came out.
Do you still feel like it is "good enough" ?
You are gambling on $300 worth of parts, (Plus locker if any) and maybe a nasty situation when it breaks going down the highway.
Do you still feel like it is "good enough" ?
Not saying you can't do it yourself, but from your description, I don't think you are quite there.
And I have to agree with Yager. Race cars are set up differently than 4x4s or street cars. They only have to last a few miles between teardowns. And they don't use reverse too much.
