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Yours may not be out, just something to check. I changed the pinion angle several times and nothing helped, so all that was left the driveshaft or the rearend.

Do you have a good valve body you can put in it? The 2-3 flare could be the adjustment on the Lokar KD cable. Hopefully you haven't smoked anything.

I'd have the driveshaft balance checked too. When I installed the Dana in my Dart several years ago I had a 1350 driveshaft built by a very reputable company in Michigan. The shaft was well over $400. I chased a vibration for years, nothing I tried worked. I was rebuilding my 727 and the shaft...

As you posted most of the time they shuck the teeth off the ring and pinion gear or break the cap on the pinion side. A 9" is a good design but unless they are in a good nodular case with a good pinion support they aren't really that strong either. My brother and I broke several in four wheel...

489's and 742's break in the same places as 741's do. Been there, done that and seen it many times. BTW, it was a good design for it's intended use.