Knocked out the gear swap on F100 from 3.89 to used 3.25. The pattern on the 3.89 gear set looked very good. First job is the pinion. Move the bearing over to the new pinion. Found a right sized piece of DOM from the last time.
I had already installed a crush sleeve eliminator. Found the rest of the shims and nut with the lock cut off for setup. Started with the same spacer size and it was close. Went down to only the thinnest shim plus the big pieces and still too loose, so machined a few thou off one big piece. Breakaway torque good so put some RTV on the end of yolk and some locktite on the nut.
Cleaned up the housing enough to work on it. Cleaned out the threaded holes. Cleaned the muck out of the side adjuster threads.
Cleaned up the ring gear bolts and installed them with locktite.
Started with the existing pinion shim of 0.015.
Set backlash with homemade spanner tool. Minimal bearing preload and did a pattern.
Drive on heal and coast on toe, so pinion out too far.
Put in the thinnest pinion shim of 0.012, backlash at 0.009, and another pattern. Now the opposite, drive on toe and coast on heal. But no shims in between so open up backlash to 0.014 and got an acceptable pattern. Measured breakaway torque, not enough so added carrier preload until I got about +6 in/lbs from the carrier and a total of about 19.
Put the 3rd back in the housing reusing the lube locker gasket and not having to clean up or use any RTV. The whole deal was a mess, but I think it was engine oil leak that I have resolved and not necessarily the axle itself. Popped axles in, just need to get some fresh 80/90 as the stuff that came out was nasty even though it has only 1200 miles or so. Also need to swap the speedo gear back to the 18 that it came with, if I can find it.