Re: Differential rebuild
.040+ is a lot of gaskets! Was this a mix match of parts? I had one that I was ending up with way too many housing gaskets, it was a mixture of parts. We ended up taking a cut off the carrier to seat the bearings closer to center.
Adding the shims will move the bearing out which will require more gaskets not less.
I would pull it back down and check first that the cups and bearings are fully seated.
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