cutting the yoke for the RE hack n tap

[bill hitchcock]

installing a new transfer case and going to cut the yoke. any tips on a way i can cut the yoke absolutly straight?

 

[EricsXJ]

I take it you mean cutting the shaft...

All I did was wrap a piece of masking tape around the splines using the edge of it as a guide to where I wanted to cut. It came out surprisingly straight and I didn't need to grind it down or anything afterwards. It doesn't have to be 100% straight but it should be as straight as you can manage to get it.

 

[Cheropair]

Ditto the tape, used the 1" variety because it was handy to get the proper spacing.

My method was a little different - block wheels, drop rear driveshaft (duh), then MAKE SURE IT'S IN 2 WHEEL DRIVE, start the motor and drop in gear (I remember reverse). I used a 4 1/2" right angle grinder with a cutting disc and a mark one eyeball to get the cut square and concentric. To get the bolt hole drilled square to the world, I started with a small bit in a cordless drill, output shaft still spinning, and went to town. The spinning stub shaft will automatically center the hole, if you hold the drill near the center - the hole may not be the eact size, but it will be square to the shaft. Turn off the motor, set in park, drill out to proper size in one or two steps, the tap. Use plenty of oil!!!

I then restarted the motor, ran forward, then reverse, while holding a small stone to the edges to knock off any burrs and create a small chamfer on the edges. HTH, Cheropair

 

[h.curtis]

Here is how I did it. Pretty easy job with these instructions.

http://www.dpgoffroad.com/rubiconsye.htm

Curt

 

[Maximus]

I agree with h. curtis, that how I did mine and it was perfect. I did do mainly continuous cutting though with no adverse affects.