I threw out a few ideas the other day and it seems like all of that has been covered many times over. Given all of the stuff you"ve tried with no success I"m going to go out on a limb and say, "The problem isn"t in the clutch". If it"s releasing, be it 1/16 of an inch or an inch then it"s released, that"s all it can do. Depending on the model of transmission it may have syncronizers. Whether that one does or not you"d have to call someone that knows more about them than me to find out. That said a syncronizers job is basically to help not necessarily stop the gears from spinning but help them mesh when/if they are turning. Since the gears usually have square cut faces/sides if the syncronizers are worn to the point they aren"t doing their job then the gears are going to grind no matter what you do to the clutch. The transmission in my "78 Jeep J10 got like this once. Like you said it ran find, shifted fine, etc, basically it had no problems beyond gringing gears on the shifts no matter what I did tp try to prevent it. I did a rebuild and replaced the syncronizers, which were worn, and it hasn"t ground a gear now in more than 10 years.
Below is a link to Spicers site. They can probably tell you anything you need to know about the transmission.
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