Rolling torque is set between 6 to 10 in Lb for manual 11 (first gen) and manual 28 (2001 and up)

Other then maybe a bit more noise, I know of no way to tell. In adjusting you need to use a new lock nut. Pic is from manual 11 but is the same as 28 and can be adjusted without being in the husing

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I don't think he used a new lock nut.....I found some info on youtube but i think it was an alpha..You just tight the nut to 80lbs...He said he set it for 5 to 6. We are going to check it today.
Is it possible he didn't set it right and its loose inside? With the drive all the way in and straight its hard to believe the noise is the u joint

I've never seen anything from merc that was "hard shimmed"....it can ( and I've done it) be done though.

was the drive shaft that slides into the engine coupler,, greased,, or dry when you removed it after the rattle noise, if it is installed dry and not greased it will rattle loudly., and rattle more when the steering wheel is turned .
if he set the rolling torque at 5-6 in.lbs.,,that will not make noise ,,unless the bearing are bad.

Alpha 1 Gen 2 preload is 8 in lb
Alpha 1 R and MR used a spacer (item 6) and were torqued to 80 ft lb. If gear sets were changed the spacer was not used and rolling torque was set at 6 to 10 in lb

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Took it apart...Checked the rolling pre-load first it was at 10..going right and 5 going left...something is out of round..removed nut and washer, bearings not turning smoothly. Large washer next to seal and ring has a rough spot in center. metal to metal worn seems like pre-load was set too tight and/ or spanner nut over tightened With an 18" torque wrench set at 120 should give a 200lb torque as manual says.I don't think a torque wrench was used.(the cause)..He is changing the bearings etc.assembly I feel better now at least we found something

Good deal, be sure to post the root cause so we can all learn.

when a drive is level with the bottom of the hull the U joints are straight and so is the input shaft so no noise.
Like I said something is wrong inside the drive.

Update...They found a inner washer that looks like it was rubbing against something.. see pics... Probably from over tight pre-load adjustment and/or as stated before no torque wrench used only the spanner tool and a hammer. Putting drive back on tomorrow and start up. Hopefully noise gone..
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And WHERE did all of that metal go???