I have changed both the output shaft, and the intermediate shaft.

I basically had to build a complete overdrive unit from spare parts. The only parts that will be original (in the overdrive unit) are the governor, and the overdrive direct drum. The entire overdrive gear set came from a 46re, it's the newer 22 degree angled gear set. I bought it as a unit, and was told that as long as it's not mixed with any earlier 15 degree parts, then it will work fine.

The intermediate shaft was ruined and the front of the shaft galled and rounded back over the retaining snap ring groove.

Have I made mistakes in my calculations with these parts? Everything has fit together in the overdrive assembly smoothly, and the thrust bearings are all oriented properly. I paid special attention to that.