XTZ Failure. After MK2 to MK2S Upgrade  

XTZ Failure. After MK2 to MK2S Upgrade

I have been trying for 2 days to get XYZ Calibration to work. The result is always: "XYZ calibration failed. . See case 2 on page 16 in the Prusa 3D Printing Handbook. It states: Please consult the manual.
First, I want to set the record: I built this printer in December 2016 and was able to get a good calibration after a minor adjustment. Then in January I noticed I was getting a bad 1st layer in my printing. I determined the Print Bed was warped. After going through several steps with Chat, the agreed with my assessment and sent a new Print Bed and Y Axis Plate and 3 U-Bolts to mount the bearings.
After reassembly I had to make several adjustments to get XYZ calibration to pass. In that case the error was "case 6) Left front calibration point not reachable. I finally got it to pass by moving the carriage forward to 103 mm rather than the 100 mm stated in the original assembly.
OK I wanted to lay out a base point showing past experience. 😉
Steps I have taken since my reassembly with the MK2 to MK2S upgrade.
1. Prusa says use a tie wrap to set the initial spacing of the PINDA in the new PINDA holder. I did that. (The tie wrap measured 1.07 mm.)
2. XYZ Calibration: Nozzle hit he bed.
3. Using 3 business cards measuring 0.94 mm: Nozzle hit the bed.
4. Using 2 business cards measuring 0.68 mm. Nozzle had a slight drag on the paper I use to protect the bed.
5. Using 2 different business cards measuring 0.5 mm: The Nozzle cleared the bed but XUZ calibration failed. case 2 page 16 of the manual.
6. Using a Business card measuring 0.3 mm: I could not get the nozzle to lock in at that spacing. I Thing the groves made in the ABS from previous adjustments were forcing the PINDA to seek the previous setting.
7. Using a business car measuring 0.22 mm: XYZ calibration failed. case 2 same as above.

At this point I was running out of options. I remembered that after replacing the warped be I had to move the carriage forward from the required 100 mm to 103 mm, I thought I would try that. I wound up with it moved to 102.6 mm but decide to give that a try.
Failed: same error as before.

Please also not that in Viewing a line on the print bed and moving the X carriage from one side ti the other I cannot see any deviation. Its perfect.

I would also like to mention that in my opinion the old way of adjusting PINDA height was more accurate. You could move the PINDA up or down by 1/6 turn on the PINDA nut making very precise adjustments.

OK everyone and anyone. If you can offer any suggestions on how I can solve this, I would greatly appreciate your input.

Carl