Re: pinion nut loose
Check that the washer is seating correctly in the pinion flange and that it's thick enough so the nut isn't bottoming out on an unthreaded portion of the pinion. I had one set where the pinion threads stopped about .250 from the splined portion of the pinion.
Those solid spacers can fake you out on bearing preload. I don't use any spacer or crush sleeve...just a little red Loctite on the pinion where the front bearing locates. If the pinion flange fit on the pinion is a bit sloppy, red Loctite or a couple of peens on the pinion nut can help.
Hope this helps. -Al
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