Transfer Case Whine

[fatboy63k10]

I have a 63k10 with a t-221 Rockwell t-case. It whines badly. I pulled it, and discovered that the bronze bushing on the front input shaft (from trans) was worn badly to the point that the constant mesh gear had slight "wobble" play and the front output shaft (to front rear) was seized onto the helical constant mesh gear.

I replaced all the bearings, turned a new bronze bearing for the input shaft and replaced the front output shaft from a spare case. I reset and shimmed the whole assy according to the book specs as far as end play, preload etc...

Now the bastard whines worse than ever.

Is this a situation like a ring and pinion where "matched, run in gears" can't be messed with or reset ever again in their lifetime? What are my options for this t-case? I know of no parts available...