I'm well aware of the procedure for getting the torque specs for the pinion nut HOWEVER, I do not have an I-beam style torque wrench so I couldn't do this process. I counted the threads before taking it off. My issue is the new seal will not seat into the rear end. The top side will start to seat in place but the bottom will not. This may have been my fault since I was in there prying and poking around thinking there was a crush seal still in there. I tried straightening the housing as good as possible but it still won't seat in place. Should I beat on this with a piece of 2x4 and a hammer to seat it in place?
I've installed a few seals but not a pinion seal. IME they all like to pop out on the opposite side if you're tapping in with a hammer. Take your time. A little, very little rtv gasket will help seal the metal to metal contact. The proper seal driver helps. Or make your own from pipe or whatever is handy. I once made one from a discarded fire extinguisher.
So good news everyone. I was able to get the old seal out. Apparently it WAS in there the whole time. Damn truck is so rusty it's hard to tell what is a part and what is supposed to come out. I didn't mess up the diff housing like I thought I did. I was actually messing up the old pinion seal thinking it was part of the housing. Popped the old seal out and put the new one in but I have a lot of back lash still when I move the flange side to side. There is no front to back play just the side to side. I set the pinion nut at the first 5 threads which is what I counted before I took it off. I've watched video's of people cranking these down with impacts and they get all the backlash out that way but I don't want to over tighten it and mess up the crush seal. So I need to just take my time and crank it slowly and try to get the back lash out, hopefully. I worked on it till about 1am trying to get this done.... It's getting old laying on a wet piece of plywood on the gravel trying to fix this damn thing.