Zero sideplay sounds like a good plan. My carrier and bull pinion bearings were still pretty tight, but had minor pitting from corrosion.
I don't know that the gears on the mainshaft would make noise since they are not in constant mesh and also since you said it was quiet while coasting. My 2-3 gear was somewhat loose due to years of plowing, but I replaced it with a better one.
What gear oil are you using? In my '50 model M I have 80w-90 and it makes some noise in all the gears, but I haven't gone through it and it's worn.
It's frustrating to have some noise after all that work. It seems like your plan of moving the ring gear over to take up the slack and leaving the pinion depth the same was basically good.
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