"I can hear the ball bearing jumping and popping" doesn't sound too good. It could be an indication of one (or more) balls that are too large. If this is not a precision ballscrew, you may not have a lot of choice in what is acceptable, but don't expect it to ever "wear in". It won't.
I don't know what kind of double nut locking device you are using, but just jamming them against one another is not the correct method of preloading. They should be spaced with a precision spacer and then locked rotationally together. In this manner, the spacer controls the preload.
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