It sounds like the wrong spool The pinion setup good in the housing? I/E good pre-load for a base set-up with the old shims?
Did you start with a bare housing?
I wish I lived closer I have a spare spool on the shelf
Gus

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64 Plymouth Savoy
493 Indy EZ's by Nick at Compu-Flow
5-Speed Richmond faceplate Liberty box
Dana 60