AMWill

Not that helps you any, but I would agree with the improper gear install theory. Usually once the gears really seat, they are "married" together and you shouldn't replace one of the two (ring & pinion) without replacing the other. In your case, they seated improperly and probably need to be completely replaced.

I know you only have 24 posts, but I see you're really suck in a bad situation. So, if you want to shoot me a PM, I'll give you a discount code to use for purchasing new gears at AM! I figure every little bit will help!

Shane