Metal flakes near end seal of transfer case, more crap.

[Coup D E'Tat]

Some slight background. When I first got the car, I had the transfer case replaced by a dealer. Maybe 1,000 miles lated, it locked up. Maybe 3-400 miles of this were on a 2600 and stock flywheel. Had it towed back to the same dealer, and they replaced it again. It hasn't stopped leaking since. There's only 16 miles on this case. I literally drove the car home, then once around the block, and it sat while I was doing some other stuff. After the case first locked up on me, and I got the new one in, I had a terrible thumping/vibrating noise that was later diagnosed as two of the four bolts that hold the driveshaft to the rear end were missing. Any chance that the driveshaft could have moved around enough to let fluid out/ruin the seal/anything?

I ordered a new seal, and dropped the case today. This is what I found -

Metal flakes
More metal
Fluid drained
Another
Third
Last

I also noticed this -

Slight gap between the bellhousing and block
Another bellhousing/block pic


Aside from having too long a bolt somewhere, why else wouldn't the bellhousing sit flush against the block? I can't believe I haven't noticed this. The only other thing I could think of would be maybe the dowel pins slid out some when I pulled it out, and didn't push back in when I torqued everything down and aren't allowing a flush fit? I can't remember how much room is allowed for the pins. The spacer plate is in there, and the car had zero starting/driving problems.

Any thoughts on either?

Thanks,

 

[Coup D E'Tat]

I tried a shorter bolt there with no luck. That seems to be the only spot not sitting flush. Anyone have any ideas before I rip it off?

 

[Coup D E'Tat]

I dropped the tranny out, and the car is going back to the dealer for another case, and I'm telling them I want a yoke as well.

Thanks guys