Hacking and tapping.

I got my h&t done yesterday and it went pretty smooth. I used a cutoff wheel in my 4.5" grinder and it cut the shaft like butter. I cut and drilled with the engine running and trans in reverse. I'm not sure that it would be much closer to perfect if it was cut in a lathe.

My only concern is that I only have 1/2-3/4 of an inch of compression on the ds @ ride height. I stuck 360 lbs of cement in the back and had a 200lb assistant jump up and down on the bumper to exercise the suspension while I watched the drive shaft, and there appeared to be enough room, but I think I would feel more comfortable with an inch or so of compression. The only thing that sucks about the situation, other than having to do basically the whole job again, is I'll have to cut the yoke to get any more room. I have almost 1.75" of splines left on the t-case, so that shouldn't be an issue.

Is it a bad idea to cut the yoke the same way I cut the shaft? (Running and in reverse)

Thanks again.
 
3/4" of travel should be fine, I have that or a little less. The yoke can be cut freehand and squared up by eye, it is not critical on the 96-01 T-case.
 
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