Quote:
Originally Posted by 35fordman
I have the same problem putting 3.54 set in my 35. The problem is with the new pinion bearings. The cage of the bearing has to fit just inside the torque tube but the cage od on the new bearing is too big to allow this. The solution is to have a relief cut into the torque tube. I reinstalled my old parts in the banjo to make sure I was seeing this right. With the pinion sleeve fully seated in the banjo, the sleeve is just flush with the banjo and the cage of the bearing sits up above the banjo housing and must be inserted into the torque tube. I measured the old original Ford brg cage od at 2.750" the torque tube opening at 2.840 and the new cage at 2.865. I thought at first I didn't have the pinion assy fully seated and in attempting to reseat it, broke the banjo. lesson learned.
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With that pinion bearing situation....it sounds like your pinion gear teeth may not be located properly, and not meshing correctly with ring gear teeth.
I just finished rebuilding a 37-40 banjo rear using all original/NOS bearings, and did not have the same pinion bearing locating problem you and the op are having. I'll post a few pics of banjo center section with pinion and bearings pressed in place later today.