I'm not sure on the 77. Maybe someone can take a picture of what they have. I did find a few pictures of what I'm thinking.

I don't know what year these trucks are but this is what I was thinking.... In the small picture you can see the rubber mounts are beside the extension. The plate is bolted solid to the bottom.

Anyone have a truck like this to verify??

Ok that looks like a 208 transfer case. Mine is a 203 so that's probably the difference. They use different extensions.

Both my 79's with 203's have the plate. I know a ramcharger I had, had a similar issue. I had to leave all transmission crossmember/mount bolts loose to get the passenger mount to go in. IIRC I had to space the passenger mount up some also, to have the engine level.

This 77 didn't have a plate and the cross member has big holes for the rubber mounts to fit in. Sure looks factory to me.
Also the cross member in the above pic is different than mine.
If the transfer case goes up any more then it will hit the floor.

The cross member in the picture has the riser bolted on it for a larger frame rail. My 85 W350 has that also. Half ton trucks would not have that part.

I've had a couple of mid 70s Ramchargers and a Trailduster that had the plate, and my 80 1/2 ton 4x4 had the plate, but those were all small block trucks, maybe the difference?

I think, looking at everything your dealing with, I would enlarge the holes in the frame and add a washer under the nut. It doesn't explain where the issue rests, but it will move the project forward without causing a huge problem in the real life workings of the truck.

I suspect that at some point, someone will come on here ans say "I had that problem and ???? was the cause, and this was the fix". Then we will all be doing the head slap and go "OOOOOHHHH!!!!" But that might be a year from now or more.
Enlarge the holes and put it together. If the fix is identified, you can address it then if you wish. Gene

Good idea.

R.

Ok I just looked at mine, the passenger mount is on the front of the motor ears and the drivers side is on the rear and mine is in an 83 4x4 with a 383 auto trans.If you need a pic I can go out and snap one.

Dont mind the rust and paint chipping, thats what salt and snow plowing do!! It will be redone this year. Here is the drivers side.

Thanks G-Money. That's interesting. Could I trouble you for another picture of the pass mount? Maybe pull the plug wire and see if you can get a shot of the lower mounting bolt.
Many thanks.

This is what I was going to reply! This is exactly what I had to do when I did the swap on my 88 ram. I couldn't figure out why the transmission wouldn't line up, just like the OP. I found an old picture on RCC. Set the mounts up like these pics and it solved the problem

I will get one for you tommorrow as its pouring out right now and I think the wife is getting worried that I keep going out in my long johns to take pics!!

http://ramchargercentral.com/articles/?sa=view;article=37

here's the link to the pics I was talking about, if it helps...

Awesome thread!