I haven't handled one of the older Smith autos in a long time, so I can't remember how the slide stop assembly and the barrel interact.
...
My point, maybe it isn't the barrel but the slide stop assembly which may be misaligned.
This reminded me of how it wasn't uncommon for some of our shooters using 3rd gen S&W's to have trouble removing the slidestop lever assembly for field-stripping.
Unless the notch above the top/front of the lever assembly is properly aligned with the slide's takedown notch, the lever won't be able to be pushed/pulled out of the frame. The reason is the way the top of the lever is machined. (It's machined that way to prevent the lever from "walking" during live-fire, BTW.)
This pic shows the raised steel "shelf" on the top of the slide stop lever's front end. I've circled it in yellow.
Unless the slide is retracted so the rear of the slide's notch is aligned with the rear of the frame's circular opening (above the front round part of the slide stop lever), the lever's raised steel shelf
can't clear the slide's slide rail.
In other words, if the slide and frame aren't aligned properly, you're basically trying to pull steel through steel, which won't work. (Ditto trying to force steel through steel for reassembly.)
I grasp the rear of the slide and frame with my thumb and web of my right hand grasping
down and around the frame's tang, and my fingers (same hand) reaching
up and around the front of the rear sight, and then I tighten my grip, retracting the slide. (Yes, you have to hold it under the tension of the recoil spring.) Once the frame notch and the slide's slidestop clearance notches are aligned, the lever's raised shelf clears the slide's rail, and the lever can be pushed/pulled out to the left.
Installation is the reverse. However, the front of the barrel's camming surface has to be out of the way inside the frame so the lever's pin can be inserted all the way through. This means the barrel has to be moved slightly to the rear (behind the frame's pin holes).
This can be done by grasping and holding the frame/slide the same way (held retracted by thumb and fingers of one hand) so the frame and slide notches are aligned again, and either tipping the gun upward at an angle - so gravity works in your favor and drops the barrel rearward, out of the way of the lever's pin -
or, holding the gun horizontal so you can use your finger to push the barrel (push against muzzle) slightly to the rear, which will also clear the barrel lug out of the way of the pin. Basically, you want to be able to see through the lever pin hole on both sides and not see the steel of the barrel in the way.
Easier to do than describe without pics.
Anyway, once I showed this trick to our shooters, they were able to both remove and reinstall the slide stop lever assembly without thinking they needed a hammer and punch to push the lever to the left for disassembly, or hammer on it to install it.
