Well finally got a wrench on the car again, last day of the year no less.
I got the pass side spindle installed. Following are the procedures that I used.
Using the Spindle Set Up Tool, place the outer bearing on it all the way onto the shoulder. Stack the spacer and the thickest shim you have onto the mandrel and place it into the housing from the outside. From the inside, place the inner bearing on the tool, and using the thick spindle washer and the nut and sleeve from the installation tool, torque to 100 Ft. Lbs.
Measure the endplay with a dial indicator. If you used a .145 shim and the endplay is 17 thousandths, you know that if you replace that .145 shim with a .133 shim your endplay will be 5 thousandths. Remember, the minimum endplay according to GM is .001, the maximum .008. You are better off to be on the tight end of that spec, as in .001 - .004.
Repeat the process with the correct spacer and confirm the correct endplay. Its time to pack the bearings. Use a high quality Moly-Graphite grease rated for Extreme Pressure, or better yet, do as we do and use Mobil 1. Pack the bearings by hand and pack the housing with a lot of grease. It doesn’t have to be absolutely full, because the spindle is going to take up some room in there, but it needs to be completely full when you are finished. You don’t ever want to do this job on this car again.
Now the tricky part. Put the outer bearing onto its race and install the outer grease seal. Insert the spindle from the outside through the grease seal and the outer bearing, and then from the inside slide on the spacer, the correct shim, the inner bearing and install the inner grease seal.
Slide the spindle flange onto the spindle flutes and screw the Spindle Installation Tool on to the end of the spindle. By tightening the nut on the end of the tool, you will draw the spindle into place and into the outer bearing. Torque to 125 FT LBS and make sure the spindle is properly seated. When properly seated, the gap between the spindle and the head of the ¾ inch bolt head that is at the top of the parking brake assembly should be about 300 thousandths, plus or minus. You will notice when more torque yields no more spindle movement. NOTE: when I did this I also did the following. torqued 3 times, 30 ft/pd hit with hammer on spindle face and threaded end, torqued to 70 ft/pd,, hit with hammer as before, then torqued to 125 ft/pd and again with hammer. I use the same technique when installing a crank and rods.
Remove the Spindle Installation Tool and place the washer with the concave side down and thread the nut on the end of the spindle. Torque to 100 FT LBS.
Check the endplay again by hand. It will probably be 1 thousandths less than you had with the set up tool if you did everything correctly, and that will be just fine!
Put the cotter pin through the castle nut and bolt everything back together.
I watched a lot of video's and read a bunch of articles and no one had the entire process. The service manual isn't even that good. Pre-loading the bearings are the key. (#17 above)