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In my 79 4x4 there is some play at the pinion bearing going into the housing. What is the allowable tolerance. All I have is a Haynes manual and it doesn't say. It's a Ford 9".
Slight gear clearance is ok, bur if you are talking about bearing looseness that is bad. The bearings should have slight preload. Gear clearance is rotating movement. Bearing looseness is up and down movement.
Doesn't sound good. No apparent bearing preload. You are close to having a major problem. I am not familiar enough with that unit to give you any help. You need to check and see if that unit uses a crush sleeve. Maybe it wasn't crushed. Maybe the pinion yoke is loose. You need to get a manual and check it out before driving it much longer.
A 9" does use a crush sleeve. If it is loose don't just tighten it up. You most likely will destroy the pinion bearings and possibly damage the gears. I would remove the pumpkin and replace the bearings with a new crush sleeve. I would also replace the carrier bearings. The 9" is one of the easiest rearends to setup. Just don't replace the pinion shim and the pinion depth probably will stay ok.
You can get the CD on you vehicle from one of this sites sponsors. You can also go to http://www.yukongear.com/ and download a free manual that shows how to crush the sleeve.
You can get the CD on you vehicle from one of this sites sponsors. You can also go to http://www.yukongear.com/ and download a free manual that shows how to crush the sleeve.
I used a similar manual to rebuild my finicky 8.8" with no problems. I doubt you will have any issues setting up your 9" to spec with the same manuals.
This was also my first rear end rebuild, gear, and LS swap. I had it checked at Randy's ring and pinion 5,000 miles later with no issues. If I can do it with my nominal mechanic skills and cheap tools... so can you!