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« on: September 15, 2019, 01:01:31 PM »
Well I'll throw my 2 cents worth in and hopefully not muddy the water too much. I had a very similar situation on a 63 Galaxie while installing a TKO 600. One key difference was that I was using a truck bellhousing which is slightly deeper than the original 63 FE bellhousing. I had a kit for a Galaxie that was supplied by American Powertrain which included a pilot bearing, not a pilot bushing. This pilot bearing was a much smaller OD (outside diameter) than the pilot bushing in my crankshaft, obviously this smaller OD pilot bearing was not going to fit in the large hole my original pilot bushing was in. The picture of your pilot bushing would appear to be the same OD as what was in my crankshaft. When the TKO 600 was mounted onto the truck bellhousing it looked very similar to what your pictures show that the splines bottomed on the bushing with a substantial gap remaining between the bellhousing and transmission case. What I did find after I removed the pilot bushing was that there was another hole in the crankshaft that I was not aware of due to the pilot bushing covering it up. This additional hole, deeper in the crankshaft, was the correct diameter for the pilot bearing that was supplied with the transmission kit. So, installing the pilot bearing into the smaller and deeper hole in the crankshaft resolved that problem for me. I should also mention that while I was struggling with this issue I had an old 352 core that I was making comparisons to with an original FoMoCo crankshaft and it only had the larger diameter hold for the pilot bushing. My crankshaft was a Scat 428 stroker crank, which had the large hole (fit the bushing) and the small hole (fit the bearing). I do have a more extensive write up about this and some other issues on the TKO installation, I didn't want to dump the whole thing in the middle of this post. If you are interested in reading the entire write up, PM me with an email address and I will send it to you.
I would agree with some of the other responses that it really looks like you didn't get the short shaft.
I would be especially aware of the crankshaft end play at every step of the way as the potential for disaster is present if end play is not present.
My kit come from American Powertrain and I had some real issues working with them and the issues I had. Interestingly Modern Drive Line actually helped me out in resolving my problems even though my kit come from a different vendor. I think all these vendors do their best to resolve the issues but sometimes you just have to work a little harder to make it clear to them what the issue is or find the right person in the organization that can fully grasp what your up against. I'd be hounding Modern Driveline on this as I think they are little more knowledgeable on Ford applications then some of the others plus it's their kit and they want you to be happy with it..