Justin,
I would look closely at the three cone nose lock bolts - are they screwed in as far as they were when you took them out?
If not, I would suspect that maybe a shim didn't seat squarely in the bore, not allowing the pinion to seat all the way. I don't remember how much bearing was visible in mine but that sounds like a lot. I don't remember even being able to see back there.
I would take the carrier out and determine why the adjusters won't screw in freely. It is easy to get them cross threaded.
Don't forget, you MUST check the gear mesh pattern.
Paul
