Mixed results. Trans shifted much smoother, with a more positive throw on the shifter. First sounded quieter, and second sounded about the same. No crunching, no grinding (except when I downshifted from second to first, which was the same behavior it had before).
BTW, you did fill the od w/ gear oil as well though the pipe plug, pass. side aft od housing?
Two ways not to grind as you have a non-synchro 1st gear.
1) Shift into 1st from a complete dead stop
2) rolling at low speed shift into neutral then second gear then first
1st gear in that transmission should not be relied upon be used to down shift to slow the truck IMHO. Anyways the old adage is...
"What's cheaper new brake shoes or a new transmission?" the answer brakes of course.
Next step is to pull that trans while your boy is still home and get that shim in as Fred suggests. Ten years or so ago Fred gave me this advice and it served me well, very well as I had the exact symptoms, solved by Fred's shim suggestion.
Jim if it's any consolation to you...13 years ago I had to take the trans out 3 times as I mistakenly placed the blocker ring in backwards and she could not go into overdrive, better pictures (such as the ones you have taken) and better information such as Deve's website links and of course The Godfather of Overdrive, Fred, (sorry Fred, couldn't help myself) is here to guide us through this tortuous, yet fruitful and fulfilling path. Last but not least you have openly discussed your adventure through all it's pitfalls, pratfalls, cul-de-sacs, successes. This has a measure of courage we all admire as we encourage you on your journey.
Regards,
Cosmo
