So it meshes fine with the stock aluminum pinions? If it's too tight with the RR pinion than a worn counter gear seems unlikely, the mesh would be too loose, not too tight. Check that the pinion is at the correct depth so the set screw isn't contacting the counter gears, make sure the sleeves are in the gearcase. If it's doing the same thing in both axles than it almost has to the the incorrect pinion. Some rare issues that I've encountered are distorted cases and bent motor shafts, both of which would be unlikely.