So I'm swapping out my transfer case and trying to transfer my old actuator over to the other t-case that I bought. These are both 246s. The actuator is a few degrees off to where I cant get the damn shaft to line up enough to slide it on no matter what I do. The case I pulled it off of locked up so I'm wondering if somehow the shaft was in an abnormal position when I pulled it off the case and now I can't adjust the position of the actuator and its now stuck in this odd position. I tried plugging it back in with the actuator off the t-case and switching between 2WD and 4WD but its not moving at all (not sure if all the different sensors need to be plugged in or not to allow the computer to send a signal to this actuator). I'm afraid of trying to force the actuator into the correct position by rotating the slot a few degrees while the actuator is off the t-case. Any suggestions?

 

Wow...either nobody swaps actuators or they always slide right now without alignment issues?