I wonder if you didn't get those "dogteeth", or whatever they are called, that sit in the "High-low synchronizer assembly" (my shop manual's term, basically the hi-lo clutch hub) in correctly. I had a heckuva time getting those assembled right on mine.

Another thought, does the shifter lever work with the cover off?

Steve Carlson - 95 Trooper LS expo rig
Serenity now!