My FSM is also a bit confusing.

1. Tighten to 94-145 ft/lbs
Loosen to 0 ft/lbs
Retighten to 18 ft/lbs

2. Install lock washer to align holes. Adjust hole alignment to not more than 20* of hole aligment.

3. Loosen lock nut about 30*-40* to adjust front hub's turning resistance - spring scale reading 2.6 - 11.3 in/lbs

Free play axial movement measured at hub - .002in or less.

Yes

One bearing moves up by the bore clearance and the other moves down the same amount.

The mental model I worked out is that it's the ratio of the bearing to bearing distance VS the height of the wheel from the spindle.

If the bearings are three inches apart and the height is 15.5" ( half of a 31" tire) the ratio is 15.5 / 3 or 5.2 to 1.

If your total bearing clearance ( both bearings combined, one moves up .0004, the other moves down .0004) is .0008 then you you would get .0008 x 5.1 of movement from the neutral position and then the same amount of movement the other way. .. Or about .010 of slop.

Basically, no matter how tight the preload, your going to have some movement. If you have a slightly worn spindle it's easy to imagine getting .030"+ of tread movement. With a layer of grease on the spindle, its hard to notice this when you slide your bearings on. When you have the leverage of the wheel to force the bearings you can feel it.

Might be nit picking... But if you have some slop after you adjust, its good to know where it came from. If there is a .001 groove in the spindle your wheel will move about .030" and if you have any signifigant wear....

Kevin

Finally got around to fixing this. Once again I'm reminded why I do this work myself. Turns out the 'professionals' who replaced my caliper 2 years ago after I bought the truck used the wrong part! Must have been one for an older LS gen 2 which uses a narrower bracket. My old rotor was worn thin enough that it didn't cause much of a problem until I replaced it.

So I got a new caliper and the bracket has far more clearance. I also tightened up the bearing adjuster just 20 degrees or so and it feels much better. Now the play is barely perceivable...just to the point where I can sort of feel a hint of it but not enough that it visibly moves or clunks when I rock the wheel. Everything still spins very easily so I believe I've found the sweet spot. Thanks for the help!