Thank you for the more detailed explanation, though forgive me if i'm still just as confused. <img src="/forums/images/graemlins/confused.gif" alt="" />

I'm not exactly sure about the "shelfs" you are speaking of. The input shaft is the same diameter all the way back except at the very tip where a bearing rides. where the hi-low assembly and the 4wd gear ride, there are no "shelfs" (if we're talking about the same thing).

IIRC, the 4wd gear (gear tera sends you) rides on top of a small needle bearing at the back of the tcase. the hi-low assembly fits right up in front of that, but rides directly on the splined portion of the shaft. when you shift into low range, the collar over the hi-low assembly slides to grab the teeth on the tera4wd gear and essentally lock it to spinning with the shaft.

are you saying the inner ID of the 4wd gear was machined too large? or are you talking about the teeth on the 4wd gear that engage with the hi-low assembly aren't meshing with the hi-lo clutch as tight as they should be?

-Rob