I had to remove the transferbox from my 2003 HSE7 Diso II because the o-ring was bad and leaking gear oil. After replacing the o-ring, I have found reinstalling the transfer box is a problem. Has anyone had a problem with the transmission spline not matching up to the transfer box? I have wiggled, shook and shaked it to death and it will not go. There is no damage but it has become frustrating to say the least. Also, can you use 75w/90LS gear oil in the transferbox or does it need to be without the LS?

Thanks,

 

I had this problem and then i realized part of the case was getting hung up on the transmission mount bracket. Double check for that otherwise if you think the splines are not matching up, just rotate the rear flange back and forth a little to line things up. You may need to lock the diff to do that.

 

Thanks groeder24. I'll look and see. If i had another set of hands it would help as well. All my friends are "busy"!