I had the same issue with my '37 1/2 ton rear axle. I ended up having a friend mill 0.050 inch off the top saddle surface that mates with the bottom saddle. It seems to have worked as things are snug. If my math is correct that would be 1.6/32 inch, approximately what you did with your lead shim. Your shim would take up the gap at the bottom where there is no load. As you know, there is a grease zerk and keeping the area greased would be important in keeping out dirt and water.
When I disassembled my axle the top of the housing was quite worn, as Dave predicted. I did not measure the wear but it was at least 1/32 inch.
I think what you have done will work and after tightening the u bolts you will be happy with the result.
Kent
Last edited by Lightholder's Dad; 11/17/2016 3:05 AM.
