ive done this twice (getting ready for 3rd) and went right on once and other time sounds like your trouble.  the more it went on the harder it got..

here is my 2c worth of tips.
get or make a pilot tool, and the leave in gear as said,
pivot the back of the transfer case up and down a bit, no matter how lined up you look you might not be, this was my prob.
this time i took one of the bolts to a bolt shop and bought 2 bolt 4" long and cut the heads off and slotted the ends for a screwdriver.  that way the trany will be riding on the bolts way befor you get to the pilot bearing.  should help alot. i hope....

Well, well, well...

Guess what the problem was???

You know those steel "pins"?  The little pieces of tubular steel, that fit over the 12mm bolts on the driver's side lower bolt, and the passenger side upper bolt?

You may have heard that you can have some problems if you don't get 'em both in there, right?  Well guess what happens when you put TWO of 'em in one position?    Seems there was one in the block, and one in the tranny when we hung it...

Now, I have to go see if my Suzuki dealer has any 09206-15001's in stock, because trying to tighten that bolt with two of them in there screws them both up bad!!!

One problem I did run into was the alignment dowles.  When I pulled the t-case, one dowl stayed in the trans.  I used a different t-case that had both dowls in it.  So when I went to put it in, it would stop 1/4" from being in.  It was late, so it took quite a while to find it.  Won't forget again!!

Good Luck.

I hate when that happens.  

Glad to hear you found out what the problem was. Did you go back with the new bell housing, or stick with the patched one.

Later,
Zig

Definitely staying with the patched bell housing - it's a LOT beefier, and has mounting holes for the two engine to tranny stiffeners.  Man, I feel like a moron!

I AM going to try the "lose the top bolt, and put the tranny and xfer case in seperately" approach, though.  I think I'll put a squirt of RTV into the bolt hole on the side that's not threaded (the xfer case side), just in case, to keep water out.  Looks like I MIGHT be in Moab by mid Tuesday at the latest.  Good thing it's only a 6 hour drive!

Update!  Found a new dowel pin at the Suzuki dealer all the way across Denver (Saudi Aurora)!  The tranny is IN!  No big deal, when you put just one dowel in each hole!  Tonight, I'll finish it up,and try to hang the transfer case on the back of the tranny!  Should be wheeling it by Saturday, and maybe get to Moab on Sunday!!!  Maybe.

Bob, quit your posting and get to a wrenchin!!!  
*grin*

Looking forward to seeing you down there whatever day it is.

~Nate

Bob, quit your posting and get to a wrenchin!!!

Don't I wish!  I only post from work.  Leaving in a half hour, or less though!!!

One problem I did run into was the alignment dowles.  When I pulled the t-case, one dowl stayed in the trans.  I used a different t-case that had both dowls in it.  So when I went to put it in, it would stop 1/4" from being in.  It was late, so it took quite a while to find it.  Won't forget again!!
Good Luck.

Look !!!  LIL TRUCK Warned you of this days ago,
All the time you though there was a secret  

Wild