I decided to go ahead and install a new ring and pinion due to the mileage/wear on the old set. So I'm back again, asking for advice on gear markings. Since the original drive pattern favored the toe, and was located at the edge, I placed an additional 2-mils of shim (0.023 to 0.025) under the head cup.
1st Marking - 25mil
2nd Marking - 25mil
The drive seemed to still favor the toe as the coast did the heel. So I followed with an additional 3-mils of shim to 0.028.
1st Marking - 28mil
2nd Marking - 28mil
Not sure, but I'm thinking the 28-mil markings might be too close to the root, with better heel to toe location for both drive and coast.
I should mention the runout on the carrier was 2.5-mils (within spec of <3mils), and the gear lash varied from 4-6.5 mils (after adjusting carrier shims) depending upon the tooth being measured. I know that is 0.5 mils out of spec on several teeth for lash, but I'm not sure what I can do about it other than try to have the carrier turned. There are no burrs on the ring gear, and I have not checked it on a surface plate for warpage - although visually it seems to be a quality gear (Bastuck).
I would appreciate any advice for the next step on this rear axle setup.
Joel