What's the BEST shade tree mechanic way to cut for the SYE hack and tap? Man show a grinder and a steady hand (yikes). Can you take the shaft out and bolt it on a work bench, and use a hacksaw to start the cut (this way you have a slow and controlled first cut) or is that 90 degrees not THAT critical to make. I can't imagine everyone doing the cut on the truck, perfectly, by hand. Any advise for a clean cut?

 

i did mine while on the jeep its much easier then u think. just put the transmission in reverse and it will start spinning and start cutting it off u will get a perfectly straight cut on the shaft and grind down the middle. it was very easy and took me about 5 minutes.

 

XJ-92-wow, that sounds awesome. Is the transfer cases supposed to be in Neutral or what?

The pilot hole, how do you drill that perfectly centered? Is there some sort of gauge to use?

 

to drill it perfectly u put the trans in drive and use a small drill bit as the pilot hole and the shaft spinnning will allow to u drill straight and centered on the shaft. i used a high speed metal and wood bit because the supplied bit (black alloy) sucks and drilled 1/4 of an inch and stopped.

 

O.K., so transfer case in drive, tranny in reverse (for both parts of the job. The hack AND tap)?

 

for the hack have the tranny in reverse and for tapping put it in drive

 

leave the tcase in 2WD

 

Yeah... Dont put the t case into 4 wheel.... You might be angry at what happens

 

I used a 4 1/2" grinder with a 1mm cutting disk ,did the same running the 242 t/case in 2wd. Still managed to bend output of t/case on rocks...
2nd time round, i pulled the output shaft, cut the splines up to the back bearing
drilled and tapped the shaft end. fabbed a flange then used a toyota d/cardan joint. 4 years later and still going strong.

 

Thanks for getting me straight on what to do! The HNT should be here late next week!

 

Took a while to get to this point, doing the HNT tomorrow or tonight. Just got my lift done by myself with jack and stands. 4 days. Only one broken upper shock mount, thank goodness. I started spraying PB blast on every bolt I touched for 4 days before lift day too. I think that helped big time.

Thanks again for the tips guys. Couldn't done it without you.

 

Good advice! you sir get a

 

just dont try to actually tap the hole with the shaft turning

 

I did my HNT as suggested, and the output shaft did not freewheel. I could turn it by hand, but I did have to grab it good. I used a 4" cutt off wheel, which I think was too small. I'd do a 5" (if they make it) if I were to do it over.

 

transfer case in 2wd, engine running and trans in drive. If the output shaft wasnt turning you wouldnt be able to move the Jeep in 2wd...