8 3/4 axle fitment weird

I'm having axle fitment problems on passenger side axle. 8 3/4 details: sure grip (clutch); green bearings; 2.76 gears, no buttons. Background: swapped from 3.55 gears to 2.76. (I pulled differential out and sent to axle technician; axles were not worked on) Prior to the gear swap, had zero issues with differential- no leaks, no grinding, no whirring noises, no clunking, turns were not a problem. Situation: driver and passenger axles installed easy. When I torqued brake plate (35 ft lbs) to driver side, I checked for rotation of axle and differential (turned it at yoke) and rotated with minimal effort. Passenger side install was easy, but there were several problems that were encountered. First, passenger side axle flange butts right up against brake cylinder whereas driver side flange is 1" from brake cylinder. Second, and this is the weird part, when I tightened the brake plate, the axle would not rotate 360 degrees; it rotated only 355 degrees and would lock-up like a rod (just for example purposes) jammed the gears. Another way to put it is start at noon, rotate clockwise and differential noon point stops at 11. When you go back to noon, turn it ccw, it stops at 1, and again like a rod was used to jam it. I remove the pass axle and check for rotation. Driver side and differential rotated easily however many turns you want to spin it. So, I re-install pass side axle but do not tighten brake plate. Pass axle goes through complete rotations, brake cylinder though still butts up against axle flange. Again, when I torqued the brake plate, both sides only allowed 355 degrees of motion. This is what gets me.
Honesty time. I'm out of my element here. I recognize there is something amiss, but my lack of detail knowledge on 8 3/4s has kept me from seeing a solution. I recognize there is a spacing issue going on, but I do not know how it could have happened with what I thought was a straightforward remove and replace job. So, I'm calling on the Moparts experts to help out. I live in Texas, and it has been hotter than f$(@ down here which limits my time working outdoors, especially for my age. I'm going to remove both axles and reinstall them to see if maybe (?) the problem solved itself because I did a better job of re-installing axles. Or the Mopar god smiled on me. I will make attempts to check in regularly for updates on info, so my apologies now for not responding in a quick fashion. I appreciate the time you take to respond.

Well detailed post.

I would have started with the adjuster but you said you have green bearings so my only thought is have you tried bolting in only the passenger side axle to see if it is an axle/side issue? Could one stud be hitting the brake cylinder?

Did the technician swap only the gears? Same limited slip unit correct?

Clutch type sure grip has 2 piece side gears , it's possible they have slipped out of alignment. pull the drivers side axle out and shine a light in and take a look at it . It's possble to get the axle in without having to take it all part . Put a wheel on the passside , set it on the ground and with a long bar thru a couple studs on the drivers side try to slip the sure grip by turning the axle and applying pressure inward on the axle .

Otherwise you're going to have to pull the chuck.

The nominee for dumb ass of the year is....Me!! So, I take the axles out, remove brake plates, lay them out in the garage, and stared at them. Low and behold- I've got the brake cylinder on the wrong side of the plate. Put it on the correct side; put the axles in; tightened to 35 ft lbs. And voila-rear end is doing what is suppose too. Thanks IMGTX and John RR for your responses.

glad it was an easy fix !
and don't beat yourself over this. i do dumb sh$t all the time !

I think the important part is that you stopped, stepped back and went for help rather than a bigger hammer.

X2

x3 ! the BFH has been used throughout time, and has caused damage a guy doesn't want at times. [it is also hard on fingers and thumbs. ]

Thanks guys. The responses got me laughing. Yes, I am getting smarter in my old age, but I did give the BFH a look. Cool head prevailed.

So.. you had the backing plate on backwards?! Did you change all that stuff too (wheel cylinders, brakes?)

If it doesn't fit, force it. If it breaks, you needed a new one anyway!

keep fixin' it til it breaks............

Dat sounds like a Furd and Cheby racer
I've learned so much from screwing up working on my cars and racing them and then having to go back and correct my mistake
I'm amazed that I still do it, HOOK on Speed, power and traction I be
Never quit learning, NEVER

I learned more from my mistakes than any book or video.

Experience is learning from your mistakes.
Wisdom is learning from others mistakes.

Glad it worked out