What did I do wrong?

as stated in my previous post ( pg1 ) this case had a 4.86 gear with the suregrip installed originally . when he went to the new off brand 3.55 gear you could not turn the pinion at all

Let me start by saying "thank you" for responding. And all the others for that fact.

I re-read your first post and did not pick up on the fact that maybe you were saying the carrier was incorrect for the case thus causing the issue. I am actively looking for a machine shop to cut the pinion for me. Not interested in going at it with a angle grinder. Wish I still had my lathe cause I would have already trimmed either the pinion or the carrier.

Dr. Diff sells new powerlok's for about 350.

Thanks. Thought I saw 595 when I checked but they are listed at 395. Might call Cass and confirm. Course the gal with my wallet has to agree. :)