By Chuck Bremer
I installed a Rubicon Express Hack 'N Tap SYE today on my NP242 SelecTrac. Most people have the NP231, but the 242 installation is pretty much identical. Of course, without much in the way of writeups, I didn't know for sure! Anyway... here goes...
Step 1: Bye-bye transfer case drop!
Step 2: Out comes the old driveshaft. It had some nicks/roughness on the yoke, which would explain the drip I was getting out of the tailcone seal.
Step 3: Remove the tailcone.
Tailcone removed, mating surface needs cleaning.
All clean, and ready to go!
The SYE kit. All parts included, including the appropriate size drill bit & tap.
Step 4: Hi-Temp black RTV on the new part.
Step 5: Installed. The green masking tape indicates where the cut will be made.
Step 6: To protect the bearing from metal particles, I covered the opening with a couple of rags with a hole in it, held in place with some zip-ties.
Step 7: Getting down to business!
I read a suggestion that you cut the tailshaft with the Jeep in reverse, so the tailshaft is turning while cutting. This method helps result in a straight cut. Like so: http://www.trailbossoffroad.com/syevid.mpg (right click->save as, please!)
Partially Cut....
All done cutting!
Drilled. I drilled the hole in 4 steps, using a slightly larger bit each time.
Tap ready to go. I used my own Snap-On tap, just for peace of mind!
Tap the hole, slip the companion flange onto the tailshaft, and viola!! I used the old tailcone and a BFH to help seat the flange, which was being slightly stubborn.
The hack 'n tap is a little nerve-wracking at first, but it ended up not being too big a deal to install. I did not have any vibes, but wanted a SYE since I am planning a little more lift in the near future and would need a new driveshaft anyway. Also, in the event of driveshaft breakage, I can remove the rear shaft without losing all my transfer case fluid, plastic Coke bottle retention method be damned!
*Chuck*
