I ordered a Trail Gear knuckle service kit to do the knuckles at the same time
that I was putting in my new gears. Everything has gone together great. Just
a couple of little issues. I have been trying to get things buttoned up, but
now I am having a bigger problem.

My problem is that I am getting about 18 pounds of pre-load on the bearings
without even tightening the spindle nut. Has anyone run into this issue?
Any ideas? Yes I have searched, both here and on trail gears fourm. TIA

 

How are you measuring the preload? Have you just packed fresh grease into the bearings? Are brakes are unattached right?

 

I haven't even put the calipers back on yet. I am measuring the preload with a spring scale hooked on the top stud. There is enough drag that it takes alot of effort just to turn the assembly by hand by holding on to the rotor.

 

You are supposed to tighten the spindle nut to 43 ft-lbs and then loosen it until you can turn the hub easily by hand. Then retorque to 18 ft-lbs.

Try that and see how you come out (maybe you already have?). FWIW, it is my understanding that the Trail Gear kits do not come with quality bearings. I always go Marlin or OEM. I hope that isn't your problem.