First off, a MASSIVE thanks to Clayton and Geoff for spending their day under my TJ today.
Second off, a MASSIVE thanks to my girlfriend's dad for letting me use his heated (70 degrees!) garage. Worked in jeans and a tee-shirt all day. What an awesome thing, considering the temperatures outside.
We started around 10 and worked until 4:30 (including a 1 hour AutoZone/lunch break) and successfully ripped apart my transfer case and removed the extra long output shaft and Slip Yoke. It's great to finally have completed this mod that I have been avoiding for years.
We started off by debating whether or not to put the TJ on ramps in the rear for working room. Due to my suspension characteristics and tire size, this was unnecessary as we had plenty of room to work under there. Then it was a simple process of jacking the transmission, lowering the skid, draining the transfer case, removing driveshafts, removing the harmonic balancer (rent the freakin' tool from AutoZone. Took care of this in literally 1 minute). Then crack the tail housing off, crack the case in half, remove the splined output shafts from front and back, and swap the shaft!
Re-assembly time was quick, and we spent a while waiting for Clayton's (rightfully) excessive RTV gasket job seal. No leaks to be seen here! Filled 'er up, and she is good to go! The needed tools list write up at 4x4explor was worth it's weight in gold for this project.
All that remains now is for me to remove the welded on TC drop brackets, and fab up some new nuts to mount in the frame so that I can have a flush mounted tc skid! Soon enough I'll be building my own, but that's not happening this week.
P.S. it's snowing! Real, sticky snow. Driveway, streets, houses, lawns, (jeeps), everything's covered!
And what needs to be fixed with the TC skid drop... we'll see how far I get tomorrow.