Trey, I'm inclined to believe that it has something to do with the roughness that your feeling as you turn the pinion. You used a new crush sleeve, I'm sure. When you reached the inch Lb. measurement, and it was a tick too much, did you back it off any?
How many inch lbs. did it take to turn the pinion with a socket on the pinion nut? You have to check that number BEFORE you put the carrier back in...your checking pinion preload only, and the carrier/ring gear will throw this number way off.
It sounds like you have too much preload on the pinion, with the roughness your describing. I hate to say it, but you'll probably end up setting the pinion up again, which is a pain. Hopefully I'm wrong.
I have another one to do for my nephew. He just bought a 3.90 gear set for his silverado.
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