Ok, I'm right at the last part of pulling it, I've got the 6 x 17mil mount bolts out and the AYC hose off and the TC has come away from the gear box and theres a gap of around an inch between both, the TC has actually now pushed into the oil pan curve and wont go any further like its stuck in the centre , I've also pushed the other side (drivers side in the US) c/v shaft out by about an inch too. I've got a bar down between the gap but it aint moving.

Should I pull the left side cv shaft right out? is that it? Why wont the thing come off the gear box?

 

You must pull the left axle. With the left axle off see an extension shaft with a bolt hole in its end. Thread in a bolt and use a slide hammer to pull the shaft. This should all be done before unbolting the transfer case. Here's a great little video showing all of this stuff.

 

Ahhhhaaaa thanks for the tip ok I'll have to bolt the TC back onto the gearbox and get that left shaft off, I'll build a slide hammer, I think that threaded rod is 12 mil

 

Up at the top, between the transfer and the transmission is a tiny o-ring in a recess. It likes to fall out and disappear. Don't lose it.