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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Today's Featured Article - Women and Tractors - Tractor Engine Repair - by Teri Burkholder. One of the great things about working on a tractor engine with your other half is that you know what he is thinking of at all times and can anticipate his every move and his next thought of what he will do. With Ben, anyway, I can tell! He'll be busy working and I’m handing him tools and he says, "give me that..." and I’ve already got it in his hand or "hand me that....."and I’ve got the portable light right where he needed it placed to see. "Run in the house and get me a...."as I open th
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