Wonder if the contact with the carrier was there from the start? Mine seemed to pattern fine at 095 with no clearance issue on first attempt. What I do not understand is why it changed after final install of the pinion bearing.
with the new bearing races installed into the case ,,, I use set up bearings for the initial assembly to get the correct gear pattern -- I always do a repeat set up using the New head bearing to double check the gear pattern ,,, and sometimes , not always, there are minor changes to the pattern requiring a slight shim change ,,,.then on to final assembly of all components .
this leads me to believe that there are slight dimensional differences in bearing cones and races.
