I recently changed the front rotors on my 2004 F-150 and searched the internet for torque wrench settings on the axle nut. To say I got different opinions is an understatement. I got anywhere from 17 lbs up to 215 lbs. To me 17 is way to loose and 215 is way to tight. I settled at 60lbs and the wheel would still spin freely but, I am reading that there is an optimal torque to make the bearings last the longest. I have no idea what that setting is so, I am looking for help.

Also, what is your opinion on reusing the axle nut that says 'DO NOT REUSE' on it?

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Also, what is your opinion on reusing the axle nut that says 'DO NOT REUSE' on it?

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I can't answer your F-150 specific question but...generally, if the "one-time use" fastener in question is suspension related, or really anything that could eff your vehicle up if it were to fail, I would replace with new. Keep in mind it's a 10-year-old vehicle, and that nut was likely designed to deform once the proper torque has been set the first time.

If it were something less critical like, say, an exhaust fastener, I'd put it back on and keep rolling.

The 04+ 2WD Front rotors use like a crazy number, 295 ft lbs or something like that.

The nut is one time use. Even Oreillys sells the nut now by Dorman.

Replace it.

So in your opinion, I need to tighten them up to 250+lbs

Not my opinion. Ford FSM.