Here's what I am dealing with ... Pilot notches are intact, 1015 fits exactly in the opening yet too high.
Is this both ends or just the front? 2nd pic makes it look liker the front pilot is a tad high off the rails (maybe not) and, angle perspective aside, it looks like the shell is not quite in alignment with the fuel tank (not that the fuel tank is necessarily straight). Could one or both LEDs possibly be holding the shell up a little? (Disregard my last, I missed that you tried that.)
I agree with tehachpaifan that it looks that the shell is not down all the way on the front for some reason. The gap between the rail and the bottom of the pilot appears to be larger with your loco than the gap with mine. The distance between the truck frame over the middle axle and the jacking pad. The distance on yours appears larger as well. And finally, in your 2nd photo there is a bigger gap at the front of the fuel tank than the rear. What puzzles me is what it could be? You mentioned earlier that you removed the light boards and the light shield. Those are the usual suspects. Without actually having the locomotive in my hands to look at, I can't really say. Is the coupler box hitting the front of the lead truck? With a 1015 there is a good size gap between the truck and coupler box on mine. But at this point, I'm just grabbing at straws. And looking at redoing a number board too I see. Wish I could be of more help.
Thanks to all who have stressed that the shell is not completely seated. You are correct. I have not determined the root cause yet but have managed to improve the situation quite a bit. Glad I hung in there and resisted enlarging the opening. I don't think it will be necessary.
The first run of C30-7s from the 1990s uses a 1015 coupler with the shim on top of the 1015 coupler box. The most recent run uses a 2004 coupler box using 1015 coupler innards. No filing or trimming is required on either set up if you are doing it right.
That only applies to the first generation 1015 couplers. You flipped the coupler box halves to change the height and no shim was used.
I was lookng for help in remembering the past, not snark. Please explain what is wrong and how to make it right.