First of all you are trying to do the impossible. You can not get a text book pattern on used gears no matter how hard you try. These gears have wear on them and there is no way that the pattern is going to look like what you think it should. Most of the time with used gears I try to get the coast side to look good and don't worry about the drive side. This is because the drive side has much more wear on it than the coast side and you are more likely to get a good looking pattern on the coast side. In your case it seems that both the drive and coast have enough wear on them that you can't get a good pattern on either side. This is why I try to do a backlash and pattern check BEFORE I take anything apart so that I know what I need to be looking for when I put it back together. I think in this case I would use the original pinion shim and hope for the best.
Last edited by big gear head; 06-23-2013 at 06:18 PM.