Poor mans' SYE

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Wrench
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Joined: Sat May 30, 2009 7:23 am
Location: in a van down by the river

Poor mans' SYE

Postby Wrench » Sat Nov 20, 2010 5:29 pm

Just thought I would share my SYE setup. I have been using this style setup for a while now on my 207 transfer case. Since I am switching to the 231, I set it up a little better:

Remove tail housing assembly by removing 3 mount bolts. Weld a bolt to the end of the output shaft (much easier than the "drill and tap" method if you have access to a small MIG welder, as these shafts are hardened and extremely hard to drill).

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Take the slip yoke, knock out the "plug" that is pressed into the end with a hammer and punch. Find a piece of round stock that has a center hole the same diameter as your welded-on bolt, and OD same as the yoke ID. Cut the round stock to desired length (mine was ~1") and weld it inside the yoke. Be sure to test-fit for proper location and U-joint clearance. Also be sure to keep the weld clear of where the nut will contact the round stock.

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Install the yoke and nut to secure it. To seal the nut from leaking fluid, I used a copper washer. You can purchase a copper washer kit at Harbor Freight pretty cheap.

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Now the shaft is solid-mounted and ready for use. I used a little loctite on the nut to keep it secure.

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This setup works fairly well for me, though it would be better if you had an output yoke that fit a double-cardan joint or U-bolt type U-joint connection. My driveshaft is just a single joint at each end with a slip-splined section in between.

It is also a good idea to install a new bushing and seal in the output housing while it is removed.
Paul
'84 XJ, '19JL

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SPR
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Postby SPR » Sun Nov 21, 2010 7:43 am

Interesting. Thanks for posting your project.
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