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Ok, we just rebuilt my 9" rearend. I took out the 3.50 and replace them with 3.89's. After setting the pinnion depth to spec's new bearings and all, the ring gear hits part of the case where the rear pinnion bears installs. Backlash is set @ .008. Can't even rotate yoke without ring gear hitting rear support bearing casting ear.
This is a factory ford 3.89 gear that I've used b4 in a different case and worked fine. So, I just swapped the gear to a different case. Both case's have are identical and have same casting #'s.
The 3.50 and down 3rd member cases did not have the relief cast into them, it is very common to grind the pilot bearing area until you have clearance. Grind it just enough, you don't want to over do it.