Thanks to all who chipped in with advice and suggestions. I cannot tell you how much I have learned from these boards since I found this site last year.

After reading all the input and studying the diagrams, we replaced the tensioner spring, thinking that if it was binding up between the tensioner and the crankshaft gear, this would pivot the base of the tensioner and provide more clearance. This operation was successful, and we were able to thread the chain almost to the top.

Almost home....We have hit another binding point and we are stumped. We can see the temporary pins coming up along the tensioner, and they are moving freely.

What else could be binding up??? we have about 4" of chain left to feed.

Tensioner is out.