I dont think I need to ding the pipe anymore. It has already rubbed the groove into the transfer case so its basically fitting now. My problem is just that Im worried about the transfer case.

glad i got an 03...

I put a 3.5 on my 03, it started out ok- then it started bumping the sway bar- (not the same, but anoying as hell) DIMPLE THE PIPE- it moves around and can still do damage-- Heres what I did- 1. mark the area on the pipe that it hits(or comes close to hitting)with a sharpie on both sides, while on the car. 2. take off. 3. dimple it- I used a floor jack handle and some wood underneath. the handle side on the jack was perfect- it looks factory!

how deep is the groove??

the groove isnt deep at all. Its more like a rubbing into the transfer case. But Im just worried itll get worse and worse til it breaks through the transfer case.

Best thing to do is keep a close eye on things. If you are that concerned about it, maybe its best to go ahead and remove it and find a downpipe that is made to fit the '05 MR's.

When I bought it I was told it would fit the MR. That is the only reason I bought it. But yea Ill just keep an eye on things. I looked at the transfer case again today and everything looks the same. Im guessing that its basically an imprint from the DP now and there really is nothing I can do about it at this point. Thanks everybody for help.

I have same issue but, instead of letting the DP rub directly with the TC
I wrapped 3 layer of thermal wrap right where it rubs

at least this way the DP dont transfer heat to the TC and it's not metal rubbing against metal

If I had a dollar for every Vendor that told me aftermarket exhaust fit properly,
I would be extremely weatlhy. Ask any muffler shop about all aftermarket
bolt-ons that come into thier shop for fitment issues.

Yea I know. Oh well. Sometimes I just trust too much and I get burned. Shouldve done more research first.