I recently rebuild my xfer case.

I must have lost the 4wd shift detent plug/ball
during disassembly. The issue is, I was very ****
when I took it apart. I even took pic's and put
stuff in different baggies.

I have the drain plug and spring, but no ball/plug.

I was having a few jack & cokes ;-) so it's possible
I spaced it off and moved the transfer case, thus
the loss of the plug/ball. I was using the tail gate
as a work surface.

I went to the local dealership and ordered a replacement.

Five days later it came and resembled what looked like a
hollow bullet/casing from a .380 ACP. It had an oil hole drilled
at the tip.

I installed the plunger PN: 1-53008217 with my spring and
drain plug.

There is no way I can shift the 4wd lever from the cab, it's
way too stiff. If I back off the drain nut (all but 5 threads)
I can shift the transfer case with ease.

From what I remember, during the disassembly, when
I looked into the case, I could see two shiny *****. One
was the 4wd indicator switch and the other was the shift
detent mech (it didn't have a hole).

I could shorten the spring...

Did they sell me the wrong part ?

 

It does sound like it is to large. I suggest stopping by a transmission shop and ask if they have any extra detent ball that is smaller or to see if they have any info if that is the correct size.