I replaced my fronts about a mont ago...I had 75K on the original bearings so I went ahead and replaced them (as I had bought new rotors too). To pack the bearings, put a glob of grease in the palm of your hand and keep working grease up until it comes out the top - you don't want ANY air bubbles/pockets! As far as tightening the retaining nut - I put it on just over hand-tight while holding the nut in a socket (for better grip) - then backed it off a little for the cotter pin to fit.
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