Viperwolf, totally agree... I'm trying to eliminate causes so I'm up for anything. Just talked to a guy who's done several D20's and the problem is that none of the suggestions he had involved keeping it in the truck. It sounds like its got to come out again which is what I didn't want but I don't see a way around it at this point...
Front driveshaft is brand new, rear is in good shape and no vibrations or shaking prior to the first T-case removal. Shifter contacting floor is a possibility so I'll look.
Couple of other observations or things to note to the CB community. When I had the Tcase out I replaced the mount bushings and even added a snubber (which had never been there before). I replaced all the fasteners to the X-member and T-case mounts....
Lastly, before I pull it out, I'm going to drive it and let it happen again, then safely coast to the side of the road and get under the truck and see if I can figure out what position the shift rails are in. One thing I did notice was that I can now shift past the 2H position. Almost like a 2Lo but I'm not sure since the front hubs were not locked... Not sure if this is adding to the issue or just an unrelated item but I thought I'd share it.
Thanks, Brad