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Hey everyone,
Thanks again for all of your posts - after reading through all the posts, I did the procedure again - and as it turns out, I did 2 things wrong:
- I overtightened the castle nut
- I installed the rubber seal improperly (one of the photographs in the Haynes manual confused me on the correct installation procedure regarding this)
Following your suggestions/tips, I seated the bearings to 20 ft/lbs, then backed the nut off and tightened it finger-tight. (As it turns out, the bearings weren't damaged at all, so I repacked them anyway and regreased the spindle). I then installed a new cotter pin, and finally the rotor, caliper, and wheel.
The hub assembly spins beautifully now with no more weird noises, or interference from the brake caliper.
You guys kick ass!
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