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Thanks Rob I will try that. Yes the pinion rotates freely and smoothly without the ring gear...and with the ring gear as well. Just when torque applied it all binds

By full rebuild I have done the following: complete disassembly and thorough cleaning of all parts; had main drive case powder coated; all new oil seals; new pinion needle bearing; everything reassembled.
I did not replace the ring gear needle bearing that sits in the case....possible that the pressure is causing that to bind?

Thinking back I don’t recall checking the rotation before I stripped it apart. Since I was rebuilding I just jumped right in so there is a chance it was an existing issue and not something new occurring. Needless to say, it needs addressing!

Sorry to come back to this but it really does need the axial play and backlash checked ...

Rob

10-4. I’ll be flipping a coin on investing in the tools or shipping to Max BMW for pro service. Likely the latter

It's possible the crown wheel needle roller has slipped out a little while the fd was in the oven. There goes your clearance.
The crown wheel needle roller will almost fall out at 100C.