Dave,
I'm glad you chimed in. Your website was one of my sources of reference.
I thought about cutting the bevel on the front idler gear but as you said, as a last resort.
The tail housing is clean and the idler pin sits in deep enough so the locking pin is inside the tail housing. the rear thrust washer sits flat against the housing.
It seems to me that the slider is stopped by the detent lever in the side cover. If I were to adjust out the amount of travel with the shifter stops (that I did install) the gear would not lock in place. Wouldn't?
JT
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