Help with VAC differential

putting the differential back in a 1949 VAC. Was careful to keep the RH and LH parts separated. new cones and cups were used matching the timpken numbers. I heated the cones in a saucepan of oil and dropped them on and used the old cups to tap in the new (using as drivers). I looked at everything and it seemed all was seated properly. I tried sticking a feeler gage under all the parts and it wouldn't go in. However, I added to shims to the RH assembly and several to the LH assembly. I can just barely turn it by hand and the nuts are about flush with the studs on the LH assembly. I don't have the clearance I should have in the spider gears and there is no backlash in the ring and pinion gears. I replaced all the bearings in the transmission itself and that went together just fine. I followed the Case VAC service manual during the rebuild.

Any ideas on how to get the clearances back in the differential? Any pointer on what to look for in what I might have missed?

Also might need some more shims. trying to put this together for my son before its too cold to work on it.

thanks,
 
When you replace a bearing, you can count on always re-shimming everything that is directly related to the shaft with the replacement bearing. If there is a bevel gear involved, then you must reset both the bevel gear's backlash, and the endplay on (at least) the shaft with the new bearing.
Also, new bearings will practically never be the same thickness as the old bearings. Additionally, two brand new bearings will rarely match closely enough to allow exchanging them without re-shimming the shaft.
 

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