Oh, something i just thought of... can someone annoyed with the whine try getting noise cancelling headphones and just turn them on (while in your ears) without playing music through therm? I was thinking about figuring out how to use the bose noise cancelling radio chip or get an EE friend of mine to build me noise cancelling speakers... but forgot noise cancelling headphones are ready made.
Well, I do believe I have this solved. I tore it down the night of my followup post(Tuesday I think?) and re-measured the backlash. It had opened up to .012. So, either I ****ed up and read the dial back indicator wrong the first time, or it opened up(which shouldn't happen w/ the already broken-in/worn bearings you'd think). Either way, here's the deal.
My factory shims were really close. .275 driver's and .277 passenger's. I swapped these to be .277 driver's and .275 passenger's to achieve what I THOUGHT was .008. Given that it was .012 when I tore it back down, for whatever reason, I had to reshim. Keep in mind my total shim thickness, which gave whatever the quiet factory preload was, was .552.
I setup my gears this time a little tighter than spec. .006 backlash. I know this is tight but I've had good luck w/ this before. I ended up with .557 overall thickness this time which obviously increases overall bearing preload a bit. I think after beating on it, I'll be right at .008.
When I drove it, it was immediately substantially quieter. I think the backlash had a little to do w/ this but mainly I think it was the increase in preload. Initially, there was some bearing noise but that has quieted down substantially after about 200 miles and several heat/cool cycles. And the best part is I reused the same gears. Yea, they only had 20-30 miles on them but you could see the wear pattern on the gears and it looked good.
Bottom line, as others have said, I think more carrier bearing preload is better rather than too little. YMMV, but sometimes it works out.