I think the bottom line is that I should have used my common sense and just put in new bearings - I always thought bearings and races wore as a set and needed to be replaced as a set. My friend (the truck mechanic) was adamant that you could reuse the bearings if the looked good and put them in a new rotor with new races no problem. I guess I should have not listened to him. The bearings have 95k on them but looked good (I know, you can't tell squat from looking at them). I thoroughly cleaned, inspected, and repacked them. I followed the procedure in the manual to the letter - preloaded them to 35ft-lbs (while spinning rotor), back off 1/4 turn, torque to 16in-lbs. I put everything together and drove it for a couple of weeks and went to get an alignment. The alignment guy told me my bearings were shot and the wheel has tons of slop when lifted. So yesterday, I put it up and found a ton of slop in there. I took everything back apart and verified that the slop was in the bearings and not ball joints, etc. by overtorquing the bearing nut (to around 40ft-lbs), renstalled the tire, and checked for slop again. Go figure, no play whatsoever. Obviously, I can't torque my bearings that high, but they shouldn't have to be tightened any more than spec to remove excess play. My only conclusion now is that the bearings are worn in a different pattern or angle than the new races and I am a douchebag for not using my common sense and shouldn't have listened to my "mechanic" friend. Would you agree? (sorry, I'm just not happy at the fact I've just created a lot more work and expense for myself). BTW, is removing and replacing races on these hubs difficult with normal hand tools (hammer, punches)? Thanks.