A904 TORQUE CONVERTER

I currently daily drive a 64 dart with /6 PB A904 transmission. My torque converter keeps eating the front seal and bushing.

Are you running a '68 or later engine (or, more to the point, a '68-up crankshaft)? If so, and the appropriate spacer ring wasn't put between the larger '68-up crankshaft counterbore and the smaller '67-down torque converter nose, the result will be as you describe.1

So I replaced with spare converter i had from a 61 dart. Turns out the ring gear is different and starter will not mesh.

Correct, see here.