If you'r getting side-to-side play, then I think you may have wasted the rear-most bearing on the output shaft.
Over the last, what 7 years that we have been tearing down t/cases, we have never seen this bearing go bad.
Assuming you bent the output shaft just a bit, then as you drive, it would be putting alot of side-to-side pressure on this bearing, and of course many hours on the highway at 60+ MPH would do damage to that bearing.
That bearing is simple to get to, and you dont even have to remove the t/case from the truck, just remove the rear two pieces and your there, but however, if your output shaft is bent, then you'r have to tear down 100% to get that puppy out.
Regards,
BigMike
ps. I would suggest replacing it with a factory output shaft for now. Don't sell yourself short, Marlin will get something out from up his sleave pretty soon I hope...that will take this problem and eat it.
