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A lot of impressive engineering in there!!

Thank you. I know you have done your fair share! <img src="/forums/images/graemlins/kewl.gif" alt="" />

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A few questions:
1. How does the transmission and t-case installation/unistallation process look like with so little space between torsion bars crossmember and t-case. I remember, I had very little space there, when I tried to fit 4L65E with NP246 behind V8 on my SWB gen1. Putting tranny and t-case on and off was really painful.

Yeah, it is not very much fun. I was able to lift the rear of the transmission up as high as I could then lift the t-case in tail-housing first over the crossmember. Then I lifted the front of the cases up to meet the transmission. So at this point, the two shafts are angled upwards. Then I would slowly lower the transmission and rotate the transfer case assembly by hand via the rear yoke until the splines lined up and everything slid together. <img src="/forums/images/graemlins/scared.gif" alt="" />

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2. How much does the shifter need to move sideways to be able to shift first t-case? Is there only 2 positions for sideways movement: first t-case high and low?

The shifter need to move nearly its full range of motion side-to-side to shift the first case. I wanted this so that the separation between the two would be very distinct and not confusing when shifting. <img src="/forums/images/graemlins/zombie.gif" alt="" />

'06 Dakota QC 4.7 6sp 4x4
'88 Mighty Max
'77 KZ1000 fun old bike