Thanks, Eddy - Actually, the roll pins holding the shift forks to the rails can't bind up the shifter - there's plenty of clearance.

I had to go out for a meeting with the County Planning Commission, but not before taking another run at the t-case. It's a weird alignment problem. With the 4WD switches and speedo gear removed, it still wouldn't go into 4L.... removed the rear cover and it shifts fine - slick as owl stuff.... found a few burrs on the rail, filed and polished it.... put the rear cover back on and it didn't want to seat with the H-L rail in the rear (4L) position.... checked the pockets in the rear cover - look ok.... put the rear cover on without the .040" bearing shim and it shifts fine.... when I add the shim, I can't get the cover on all the way when the shift rail is all the way back. Since the shim adds available depth for the rail to operate in, you wouldn't think that would happen, but with the shim in place, the cover is actually pushed rearward .010" as the rail moves back into the 4L position (yet it doesn't without the shim <img src="/forums/images/graemlins/scared.gif" alt="" /> <img src="/forums/images/graemlins/confused.gif" alt="" />). The only thing I can think of at this point is that maybe the bearing recess cut into the rear cover is slightly off in transverse alignment - iow, not 90* to the rail axis - and crowding the rail to one side. I don't want to open those rail pocket up, so I guess I'll keep polishing the rail until it works.

Frank