Gotcha. Well, we messed with it some more and I just got back to Houston. We did a final adjust and got the pinion angle closer to the tranny/driveshaft angle. The vibration was gone and the truck felt smooth (I absolutely think it should still be dialed in).
I would say the most difficult things we encountered were:
1. The upper rear shock mount bolt - We had trouble getting a wrench, socket, vice grip, etc. to sit well on that bolt. If whom ever is reading this has never removed this bolt it is hard to understand why it is so difficult. Basically the frame is right next to the nut and thre is a little divot essentially to accomodate the nut/bolt. However this divot is not very big, so fitting anything of the nut without hitting the frame/divot is difficult.
2. Getting the upper ball joint to separate from the spindle- we had a 6 foot breaker bar that my buddy was pushing the lower control arm down while I hit the spindle (at the UBJ location) to try and break it loose. This worked almost immediately on the right side (we struggled prior to breaking it loose in this fashion) but on the driver side it was hell. It was definitely not coming out.
The video David ram posted was very helpful. After watching my buddy took the UBJ nut and threaded it down to the bottom to act as a larger surface (than the flat part of the UBJ bolt) to tap upwards with a hammer. Mind you we already tapped the bolt upwards before which did nothing. Though as soon as he did that and gave it 2 taps it dropped immediately.
3. Setting the pinion angle correct. This can be alittle confusing and I wish I had photos and a to draw a picture to show everyone what we experienced.
I am going to do a thorough write up when I have time. I am pretty wiped right now. I do appreciate everyone's input and advice during this install!
We installed the following:
Belltech 2/4 lowering springs
Rear only** Street Performance Shocks
Hellwig rear sway bar
Spohn Adjustable Upper/Lower control arms
Spohn Adjustable panhard bar.
Moog F-150 Sway bar end-links
Mufflex 14" Muffler
I think that's it....
Impressions: I drove the truck pretty easy on the way home (cruise control 75 for most the way. Accelerated slowly. Did not take turns hard)
It definitely feels stiffer overall, front and back. It feels tighter and more planted in turns (even when not pushing hard). The exhaust sounds nice IMO.
All in all I am satisfied and am anxious to push it hard to see the true difference. I will say I hit a few bumps and they were brutal.... and these were not huge bumps with tons of speed. They definitely felt like they bottomed the rear out. I don't know if they truly did, but it sure as hell felt like it (I have driven very stiff suspension vehicles before, so I have a good idea of what stiff and low feels like).