I've checked a number of sources now for clearance specs for rear output shaft for the transfere case, none found.

How much play are with talking about? (1/4,1/8 inch?)

You're going really quite hardcore with this gearbox Frank, carry on at this rate and you'll be above factory QA specs.

As for the lone post, it was an interesting read, just coz no-one immediatly ran to your aid doesn't mean it's a bad post.