I had a similar issue. (gear diff measured wider than the ball diff). It was fine until I tightened the case bolts. I ended up playing around with different manufactures diff.bearings until I found a set that let me get the cases "tight enough" with no binding. We are talking very slight differences in bearing width..not enough to measure with the crappy calipers I have...but enough to make a difference once it was all bolted up. I don't know who's bearings I ended up using...must have 100's of different ones throughout my years of racing lying around. Maybe try doing a sandpaper "rub" (ie.diff ring sanding) on the side bearings? Never tried this but it might work..
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