I had exactly the same problem but only on one gearbox. I took out one black shim on the pinion shaft and put it together and it was very smooth.
I then read on an American forum that you should not change the kit shims and build it as per instructions and it will bed in.
So back in bits again and decided to wet and dry a VERY small amount of flashing which was noticeable from the rear of the pinion. All shims back in and it is smooth now.
Not run it yet though!
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