I agree, coast pattern looks perfect, drive, not so much. Im not sure what that means. I would say that your backlash was too great, but with .003 backlash that has to be at the bottom of the threashold. I think you would want to move say .003 worth of shim from the non ring gear side of the carrier to the ring gear side carrier bearing and try to move your pinion back about .006. You are going to have to play with it. Unless someone has a better answer...
My D60 went in with a first time go, the D44 took about 6 tear down and rebuilds before I got it right...