I recently put a new clutch in and have the transmission bolted back up and now I'm stuck again installing the transfer case. I believe I got the splines lined up but but dont know for sure. when I start tighten the bolts up they are super tight to turn. I can see a small gap (about 1mm to 2 mm) between the transmission and transfer case. How do you all line the splines up and when they are lined up does the transfer case sit right up against the transmission or does the bolts bring them together? Thanks


Also do I need to remove the passenger side shaft that goes into the transfer case?

 

I have removed/reinstalled my clutch, tranny, T-case twice - I don't really know how to explain it without being there and looking at it with you. I personally followed this guide and I was able to get it.

http://www.evomoto.com/tech_articles..._article_id=27

The T-Case should slide on probably 90% of the way with just a bunch of wiggling, you can also grab (with your hand that is not supporting it) the output shaft and rotate the mechanism as you wiggle it.