I bent my baffle behind the inner bearing cup knocking it out and had to get a new one. It was thicker, so I had to adjust my shim packs to compensate for it.

Any chance one of the outer shims got stuck to the bearing or fall off during disassembly and you didn't realize it?
Same brand of bearings?

When I was shopping for a rebuild kit i noticed there were ones for front 60s that only came with a crush sleeve and no outer shims. Had to really compare some of em to know that I was getting what I needed.
I ended up ordering a JEGS brand one. Came complete with two different pinion seals, plenty of shims, ring gear bolts, and Timken bearings.