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There may very well be a gasket for that location. I just haven't seen one for sale. Rtv works fine though.

There isn't really a gasket for the knuckle to spindle I have seen. I just use rtv. Works fine.

Yup. Beats bleeding the brakes just to change an axle boot.

Yes, put the hub assembly on, then outer bearing, then seal, then the first lock nut. The rubber lip on the seal should face the bearing.

1. The grease inside the hub is extra grease for the wheel bearings. 2. I like to put a light coat of grease on the spindle just for rust prevention. There isn't anything that rotates on the spindle so it doesn't need to be lubed. 3. The outer seal goes on after the outer wheel bearing is...

Woops sorry. No the thrust washer is on the back of the u joint.

Hit those burrs with a file like ford mechanic said. As long as the seal seats good in the retainer it should be ok. Or if you have a few pennies (ok more than a few) I can hook you up with upgraded inner seals complete with new retainers.