Intermediate gear and output gear don't line up.

[Ed Menees]

I thought I knew what I was doing but it looks like I don't. Finished shimming the rear bearing. I used .015 worth of shims. I didn't measure the end play but you can see the slightest amount of play. Just before i put the bottom cover on, I noticed that the intermediate gear and the output gear didn't line up. Looks like a little less than an 1/8th of an inch. The output gear is farther towards the front. I should have taken a picture but was in a hurry to get it done and put the cover on. Now I'm second guessing myself. The only thing that I can think of that would affect the alignment would be the thickness of the front housing gasket. I used the standard gasket from the kit. The bearings were good so I used the same ones. The tabbed washer and snap ring are in place.
The intermediate gear is pretty much fixed with minimal end play. (New thrust washers, one on each side.)
Do I need to tear it down again? If so what could I fix?
Any ideas?

[Ben Dover]

Rear Output Shaft endplay is 0.004"-0.008" If you can see it, it is probably too much.

[Ed Menees]

Less end play would only add to the problem.

[Ben Dover]

You didn't put something in backwards did you?

[Ed Menees]

I will have to remove the bottom cover tomorrow and take some pictures. The only thing that could possibly be in backwards would be the low range slider but that has nothing to do with the output gear position. .015 worth of shims seams to be on the small or thin side which again indicates that the whole shaft assembly is too far forward. The front bearing appeared to be smooth with no slop. Again the only way to move the entire shaft assembly forward would be to have a 1/8th inch thick gasket on the front housing which I don't.

[Ed Menees]

OK, I figured it out. It's too embarrassing to explain. Stupid, Stupid, Stupid.
Now maybe I can get to sleep.