What gear is everyone running

I have to disagree.
I just put a brand new Richmond 4.10 with all new bearings etc. Suregrip I run has .001 run out, set up pinion depth and back lash perfectly with depth gauge and dial indicator. They are noisy and the Richmond name is no longer stamped on the gear. Google it and you will see they were bought by US Standard or something.

Then your setting is wrong. The gear settings provided with the gears is only a guideline. You always go by the gear pattern left by marking compound.