8.25 Dakota Gear Swap Wont Fit.

Its 8.25. The bearings will no doubt need changed but I cant figure out why the carrier in rubbing. It has small teeth around the perimeter of the carrier that rub the housing. The actual gear seems fine and all numbers point me to an 8.25. Need a different carrier I guess. Must be something a little different about this one. Pinion and pinion bearing fits fine.

You need a different carrier, one that will fit 2.94 and higher numerical gear sets. The carrier you have fits 2.73 and lower gear sets. The Dakota ring and pinion will not fit an early 8 1/4, the pinion bearings are a different size, as you found out.

See what he posted above in blue.