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lippy,
Sounds like you have found the problem area, seems like the transmission input shaft is engaging too far into the crankshaft / pilot bearing and bottoming out. Not sure which bell housing you have, but on page 12 of the ERA FIA manual (same as the 427 manual?) it states for the TKO 500/600 that some bell housings require a 5/8" spacer.
I used a quicktime bell housing & TKO 600 and had no fitment issues on my 302. What bell housing are you running on your 427?
If you pull the transmission all the way out, you should be able to measure how far the input shaft protrudes past the bell housing / engine block mounting plane. There should be a spec for what the maximum length is for that dimension. If it's too far, then you need the spacer.
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