ok so i decide to do the job by myself and on my garage floor( I know bad idea) it wasn't really that bad with loosening the sub frame and using a cherry picker. So i got my new clutch on and trans installed. Now the major problem is my transfer case, i can throw it up on there and it slides on the splines and dowl pin, but it stops with about a 1/4 gap between the tansfer case and trans. I tried tightening it up carefully and got nowhere. Any help or tip at all would be greatly appreciated

 

I used a weighted rubber mallet to tap the t case on a bit after I knew for sure everything was properly lined up. Get under the car and tap it around and do the same for the top.

I then put all the bolts in and worked my way around each bolt making sure not to put very little stress on each bolt as I did this in a rotation kind of like the pattern of wheels or head bolts so the tcase wont go in **** eyed or cause too much stress on any part of it. The transmission and t cases on these cars fit pretty snug.

FYI: I generally don't prefer this method and always try any other way before I use bolts to walk a part on. This can be dangerous to the part if you don't know what you're doing.

 

Might be a stupid question - but did you already install the output shaft that goes through the driver's side transmission? If so, that will do it! If not, try doing what graphic suggested.

 

when all else fails .....BFH

 

I did mine about 3 times within a month and that gap was always there....i just went around tightening the bolts little at a time and it slowly closed

 

hand tighten all T/C mounting bolts so the heads sit flush on the T/C. then wiggle the T/C gently. it should pivot off the bolt heads & slide on slightly (1/8"-1/32"). repeat the process until the T/C is flush with the Trans.