So, gearing question. I went over setting up my HP35 last night.
Nominal checking distance for a dana 35 is 2.095". My new pinion is scribed with "2.100" on it, and the old pinion just has "0". So I take that to mean the old one happened to set up exactly at the nominal distance and my new one would be "+5". So to start with I'd set the pinion 0.005" deeper into the housing.
Problem is on the old one, there were no shims used. There's the oil slinger between the pinion bearing and the head, and behind the inner race in the housing there's a baffle of sorts, but besides those two pieces (which I have in the install kit, and measure the same) there aren't any shims to remove.
So the inner baffle is 0.018"; in theory I could omit that and instead build up 0.013" of shims behind the inner race. Not quite sure of its purpose.
Or I'll just try patterning it with the same as old and see how it lines up. A little closer to the center is probably not a bad thing.