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When I put the new lower unit in to old upper there is a small gap on the aft end by the anode between the halves. I think that as long as its tight by the oil passage it should be good am I incorrect in thinking this.
There really should not be a gap. How big of a gap are you talking about? If you mean just a couple of thousands, then it might be okay.
Is it possible that you had an alignment pin stuck in the upper, so now the new alignment pin is butting up against the old pin?
Also a possibility is when the lower went into the upper, it pulled a little aluminum off of the upper housing efefectively reducing the depth of the hole so the pin won't go all the way up.
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