So I installed a new tranny and I removed the transfer case output shaft (connects the transfer case to the axle) but now I'm having trouble getting it back in all the way. It seems like it's in as far as it can go but when I put the axle on, the axle sits about an inch away from the transfer case.

I've removed the transfer case before and removed/installed the same shaft without any problems, the only thing that has changed is the transmission but I don't see how that should affect anything. Does anyone have any ideas of what might be going on?

 

Do you have the transfer case fully bolted back to the transmission. I know it was a complete PITA to bolt back up. It seemed like it didnt want bolt on. Is it flush?

 

I actually just figured it out after talking to a friend. It seems the axle wasn't going on all the way (drivers side went on smooth). The C clip was causing a few problems on the passenger side. All fixed now, thanks for the suggestion

 

needs a bigger hammer!