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The NeverEnding Story III: 2001 1500 4x4 9.25 Rear Axle: Gear Contact Pattern
2nd Gen Ram Tech1994-2001 Rams: This section is for TECHNICAL discussions only, that involve the 1994 through 2001 Rams. For any non-tech discussions, please direct your attention to the "General discussion/NON-tech" sub sections.
So to re-ask a question: Would new bearings on old pinion & carrier with the old shim really be that far off of pattern?
You are "assuming" that the new bearings are exactly like the ones you removed. Depending on who made them they may differ slightly(closer or farther away) from the ring gear. So if you can't get the correct pattern moving the ring gear moving the pinion is the only other option. Get a set of various thickness shims and then put the smaller ones in first. if you cant get the correct pattern use the larger ones. With the correct combination you will get the pinion where it needs to be.
Pinion depth tools are fairly rare. When I went through training for Randy's/Yukon I was in a room of experienced gear guys and the consensus was none of them used a pinion depth tool......basically because 99% of the time you're referencing off what was already in there and when you purchase new gears they're scribed to let you know if you're likely to need to add or subtract a few thou.
I'm not saying pinion depth tools don't exist or can't be useful -- just that they're more of a specialty tool even within a specialized field.