[ddruker]

Yes you have it correct. Part of the procedure is to lock the transfer case in position before you separate the transmission from the engine. And keep it locked until you rebolt the transfer case to the flex plate after reinstalling the transmission.

As you said, after I reinstalled the transmission, I expected to be able to turn the motor with the transfer case still locked. I expected the flex plate to be able to turn against the locked transfer case. It does not, it appears the be a very strong friction fit between the two. I can get it to move a bit, but it takes much more force than I car to impose on my crank bolt for the roughly 30 degrees I need to rotate the crank.

I did find one reference on the internet to this happening to someone else, and his solution was to resplit the transmission from the engine by an eight of an inch and then move the crank and flex plate into the proper position.

Also note there are four holes in the crank pulley - three corresponding with the locations of the flex plate mounting bolts when they are in the starter hole area and one representing tdc.