Yes, it seems like you need to add a shim or two. I don't know why it's slack like that, but it seems to be regulated that way unless your gauge is off... but if it's slipping, the gauge is probably right.
I would probably go in through the lift cover for the purpose of re-shimming the valve. I think I did that in place last time... but you are right. It's not a small job. Cab floor comes up, priority pack off, unbolt all the linkages, remove the remotes, unbolt the lift cover, bolt a piece of chanel to the cover and clamp that to a fork lift or pallet fork of some kind... then lift the cover an inch or two. Remove the load monitor link at the right rear corner, then gently keep lifting and wiggeling until you get the cover up and out. Why not go through the lift cover while it's off....
While you're reshimming the valve, make sure you don't get into the cooler relief valve instead of the system relief you want.
Othe than that I think you covered all the bases on testing, or at least all I'd have checked. Re-shimming is where I'd be heading at this point...
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