JAMMAN

Owns A Torsen

Joined: Mon Sep 18th, 2017
Posts: 5501
Name: Jim Occupation: Design and Innovation Interests: RBV's, Computers
Reputation Points: 8895
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From opinion, setup 2 seems more logical.
BUT even though .004 extra might take it out of spec (as in #3) in one of the tests, you have no idea how close to "specs" the ring or pinion were milled/rolled/ground whatever method they used, and you have no idea how close the bore of the pinion shaft area is to your axle shaft bores as far as an intersection point.
The backlash I would place dead last in the importance of the collective criteria.
ALSO once they wear for a while the contact should actually get better (I've noticed this with gears in lathes and presses) but the backlash will suffer slightly.
I don't know how it equates to backlash but I have seen pinion slop where the driveshaft would move about 5 or 6 degrees before engaging fully without any noticeable clunk while driving and coasting.
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