I really hope that whomever sold you that "roached-out" Pitman arm wasn't one of the folks that I suggested for you. You need to send it back to the guy with clear instructions where he should "INSERT it SIDEWAYS"!
Nevertheless, a '40 box with a '40 Pitman arm in a '36 has been done too many times before now.......it WORKS! The frame dimensions are essentially the same as a '40. Distances are similar. One thing that everyone is forgetting is the interference you HAD with the king pin LOCK PINS when inserted in the NORMAL direction with the spindle stop NUTS on REAR side of axle because of the disc brake calipers.
As NEAL in CA stated, "the ACORN NUTS must limit the spindle movement-NOT the steering box internals"! As MART attempted to explain earlier, turning the lock pins around (with the acorn nuts on FRONT side of axle) is not the same as NORMAL. This is most-likely why you have gained more turns lock to lock. And this is also where the ACKERMAN theory comes into play. With the lock pins inserted normally, the spindle on the side MATCHING the direction of your turn (left spindle/left turn) is the spindle which contacts the acorn nut, acting as the STOP. That same spindle is ALWAYS the spindle located closest to the INSIDE of the turn (circle). As such, that spindle is ALWAYS turned TIGHTER (more degrees) than the opposite side spindle. ACKERMAN always turns the spindle on the INBOARD side of the turn to a greater angle than the spindle on the OUTBOARD side of the turn.
Now, with the lock pins and ACORN nuts on the FRONT side of the axle, the spindle that makes contact with the acorn nut is now on the opposite side of the vehicle. As in the case above where we were making a LEFT turn, and we NOW make a left turn with the acorn nuts on the FRONT side of axle, the LEFT spindle is NOT the spindle which will make contact with the acorn STOP NUTS......the RIGHT spindle will now contact the acorn stop nut. And what you must not forget is that in a LEFT-hand turn, the RIGHT spindle turns to a lesser degree than the left spindle (because it is on the OUTSIDE of the turn (Mr. ACKERMAN). So, the limiting spindle is now allowed to turn to a much greater (tighter) degree, allowing the left spindle to turn even tighter still. That is the main factor for your number of turns of the steering wheel being greater, lock to lock. This would also explain your tire hitting the frame rail......it's being allowed to turn to a greater degree than Henry designed for. In addition, the longer C to C distance between the holes on the '40 Pitman arm will also ADD to the degrees of turn to the spindle. So, I think George can finally quit insisting that your '40 steering box has the wrong worm gear. Or maybe not! DD