Why thank you gentlemen :tiphat
You know I was worried about damaging the bearing caps too with torquing them down to much, but you will know when there are tight. I just don't recommend using anything other than a wrench to tighten them(no air ratchets or impact guns). I think that would be what utimatly prevents damaging them. That and adding a little lockttie on the threads to make sure everything stays where it is. I'll wind up driving the truck around for a day or so to break everything in, the go back and re torque everything to make sure nothing wiggles its way loose.
The intermediate shaft ran me $375. That includes the yoke(which ran about $70 on its own), and the straps. So for a short shaft like that around $300 depending on length and what size U joints you are running. I know my rear driveshaft will run a little more only because the AAM rear I believe runs a 1410 series U-joint, the T-case output is a 1350. I'm also not set on going with either a double cardan or standard 2 yoke shaft... I'm going to call up Tom Woods and see what he recommends.
Dave if you haven't found one yet I can recommend a great place for transfer cases where I got my divorced 205. The guy rebuilds them all really well and his prices are very reasonable.