Rearend Blues! (kinda long)

[90'5.0 Conv]

Ok, I'm beyond the point of being frustrated! I don't know what else to do.

For anyone that doesn't know, I bought a set of Ford Racing 4.10 gears to replace my existing 2.73's. I've used all new bearings and all the original shims. I asked before if the original shims would work with the Ford Racing gears and everyone that responded to my post said they would so thats what I used.

Here's what I've done so far: I have everything put together, the ring rear assembled to the T-Lok, the pinion bearing pressed on the pinon (all original shims). First, I put the pinion in with the crush sleeve, bearing, oil slinger and new seal. I torqued it till there was no play then turned it about an 1/8th turn. Everything seemed good and turned fine. Then I went ahead and put the ring gear T-Lok assembly in the housing. It was a real tight fit with the original shims. (Not sure how tight it should have been) I did manage to get it in and everything looked good. I spun the ring gear and it moved very smooth.

From there, I went ahead and put the main caps on. After I torqued them down, the ring gear and pinon were seized up against each other. The ring gear is not rubbing on the housing or anything. I loosened the cap bolts up and proceded to bang the ring gear assy back out.

I came on here and asked what should I do and more people thought that I needed to get a new crush sleeve and try again so I did that. I torqued just till there was no play side to side and left it at that, put the ring gear assy back in and the same thing. Pinion and ring gear froze up on each other. I don't know what else to do.

Everyone seemed to think the original shims would work. Are they supossed to or not? Should the pinon gear be so hard to get out after the nuts backed off of it? I beat on that thing for eternity trying to get it out. Should the ring gear fit really tight? Please give me any advice or experiences that sound similar to my problem. I really appreciate the replies.

Thanks Everyone

James