MK3 headache

I am replacing a primary chain on a MK3. It was so stretched out that the chain was wearing grooves in the bottom of the primary case and a few other spots. The tensioners were extended a long ways and the slipper pads were coming loose from the shaft. By pads I mean not just the rubber but the entire piece of steel with rubber bonded to it. It FLOPS on the end of the shaft. Disaster was not far off. So I ordered a new pair from OB. The chain is a renolds replacement. I replaced everything with no problem until it came time to install the carrier for the alternator which is also the outrigger bearing for the anti-backfire unit. The shaft was at least 1/8" away from the bearing hole. After much fiddling I could fit shaft A into hole B but the gears would be binding. Test #1, I tried it leaving out the big gear for the sprag clutch. The shaft fit easily into the carrier. It moved freely foreward and backwards and the unit would spin easily. Test #2 I removed the unit ( the anti backfire unit) and tried with just the big sprag gear in place. It moved quite freely also. Test #3 I removed the sprag unit and fit the gear + anti backfire unit and then the carrier. Both had plenty of free movement and I would be happy.
However, when I reinstalled the sprag everything bound up and the shaft was way off from its hole in the carrier.
I have pulled this apart dozens of times and checked every piece for damage or wear but still no clue. With the sprag and gear installed (but no carrier) I can easily turn the gear in one direction (clockwise) with no sense of anything wrong with the sprag . Any ideas?

Dozens of times ? You should have asked for help sooner. Sorry but it sounds like a machinist is required. The sloppy worn chain caused other problems with it.

there are spacers, 17,21,23 that need to be installed the correct way. Also if you use the drawing and item descriptions here to help you describe the parts it would help us arm chair internet mechanics remote wrench.

the AN drawings are a great resource. the spacers mentioned are in the correct way. I began the project at 8 pm, stopped at 2 am. after trying every possible variation. I finally tracked it down to the sprag but have no idea why the problem exists. These parts are all expensive and the sprag is somewhat fragile. I have to make sure all these parts are free running. I tried to figure anyway out of this. Nothing looks bent, everything looks to be in good condition. All the rollers in the sprag have free movement. The parts will all fit and work until I install the sprag then the gears lock up.

FWIW are you sure you are installing the sprag so it spins freely in the correct direction? Also, and I’m
not sure if this is possible, are the “bearings” in the sprag flipped in the wrong direction when you are installing it into the unit?
IIRC, I think it is possible to put the hydraulic tensioner body, or maybe it was the out side plate in upside down and foul the gears. I remember having an issue similar to that a long time ago but I can’t put my finger on what exactly it was.
Pete

problem solved. The inner primary cover has a mounting stud and I didn't catch it for a long time but it had loosened on the cradle and allowed it to drop enough to bind the gears. I got someone to pry the case upwards until the two gears had free movement and tightened the nut.

O.K.
Ride on.