Hi Dave, Had some time today to delve into this problem, well, not so much a problem, as you have already detailed the "fix", which I believe, is a good way out. The parts listing I have on the MF 165 multi-power, shows two different shear tubes. Up to serial no. 147509 is part no. 880070m3, and from ser. no 147510 uses part no. 1871925m1. The first tube is 5" long, but am unsure of the length of the second one. So a possibility of the second being slightly different in the dimensions to the first? As we are talking about a 1/16" being the issue. But, there is also a third tube shown in the listing, fitted to the 8 speed transmissions up to ser. no. 593198. Part no. 880 069m2, I don't know the length of this part. There will not be a difference in pinion length, as the same pinion will be used for all builds. All transmissions use a drive-shaft part no. 886366m91, so I don't believe there is a issue here, either. So what about the pinion, is it lock tabbed or pinned? If it is an upgraded model with "wet" brakes, I imagine it should utilise the later pinion nut, which is pinned to prevent it loosening. There is usually two to four threads on the pinion showing, when the nut is tightened to the correct "torque". As the shear tube sits directly onto the pinion nut, the position of the nut when tensioned could be crucial. Maybe check this first. The second thought I had, was that the end of the transmission shaft may not be where it should be. The rear gearbox bearing on the output shaft, has a circlip on it that locates into a recess in the housing. The shim(s) are then fitted and the front thrust plate of the hi-low unit fitted, so the circlip is "sandwiched" between them. Could the wrong bearing have been fitted, with the groove accepting the circlip being slightly more to the front of the race, at some stage in it's life, thus causing the shaft to be "sitting" rearwards more than it should? Apart from those couple of thoughts, I am unable to answer your question. Maybe one of the other knowledgeable gents out there can give you some more clues, regards for now, Evan.
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