For anyone following this thread,
Looks like we found the issue.
Bent teeth on the flywheel
We built a stay for the DMF to keep it in place that worked off the teeth on the starter ring - and also had the pin in on the front to stop any movement while it was tourqued so quite sure this must of happened during shipping.
Just missed the dang thing
Here is a pic - Top is the new - bottom is the old.
Still cant believe I missed this.
