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I had a similar problem when I installed a new distributor in my 96.
It seemed that the hole for the roll pin in the gear was off a little, or the gear itself.
I ended up using the gear off my old distributor and then it went in correctly.
Have you used durabak before?
what color are you thinking about using?
I was just looking at their web site and ordered a sample of the smooth blue and white.
I don't understand why everyone uses a bunch of extentions from under vehicle.
I just reach in from above with a wrench or a 1/4" drive ratchet with no extention and 11mm or 7/16 socket.
Mine is a 96 4x4 auto.