my first 742 case rebuild, need alittle advice please

your pattern is junk --- please do all here a favour and start over --- put the .090 shim in and then do a pattern check ---and adjust from there --- post the pics and we can help you better --- in the 40+ years i have been building differentials -- 742 cases are almost always in the .090ish shim range ,, unless the large pinion race was not seated completely into the case or the gear is cut way off tolerance.
you did check the bearing bores of the case for distortion/ high spots that can occur from driving out the old races -- i see that a lot and need to be corrected ( filed down ) before installing the new race.
you can see my work in kijiji ad 1235973203