Refresh My Memory...Did The 3.84 Gear Come Out Of The Zetec Tranny??? If So It Seems Odd That You Would Have A Problem There, Many People Are Running The Zetec Final Drive W/O Problems Of This Nature...It Is Still Seeming That Your Shims May Be A Bit Out Of Skew...Or Possibly That One Of The Press-Fit Bearings Is Hanging Up Or Not Seating Properly...I Did Not Personally Install My Quaife (Shimming Scares Me On A Part As Vital As A Differential) But I Watched Mine Being Done And It Did Take The Technician A Few Times To Get The Shims To The Correct Tolerances...But The End Result Was No Endplay and my axles spun freely with no Problems...But Again I Am Not Using That Ring Gear....
Not Sure If This Helps Any But Hopefully Brings To Your Attention An Oversight Or Idea Of The Problem!!!
