You have to wear the "new" off the gears. It is a pain the first dozen or so times, but it will get easier. Try Locking in 4HI, stop, switch to 4LO, slowly let out the clutch while turning the steering wheel. Repeat as necissary, it will go in. Once you get it figured out do it once a week for a couple of months to get things working smoothly. After 15-20 engagements it will slip right in. It takes a while to break in a virgin transfer case.ruger11mcrdpi said: