I was between jobs, my child was sick, and my dog was dying. I agree I could've solved the problem by starting the process immediately when I separated from my last employer. Life happens.

I have documentation to show I made a best effort attempt to repay the loan in time (official check, fedex tracking numbers, etc), but I won't know if its good enough until I file next year's tax returns and challenge the 401k provider's 1099-R.