Pre-installation Notes
This kit was fairly easy to install, but would have been MUCH simpler had the manufacturer included all the correct parts and been more clear on their instructions. It irritates me that so many manufacturers out there can't provide clear, concise instructions WITH photos to aid installation for the novice. I'm by no means an idiot when it comes to mechanical work, but just like a lot of people, I learn as I work, and, yes, this was the first time I had done any work on a transfer case before (except when I had to lower it 2" for a suspension lift), therefore it was a learning experience.
Altogether it took me 5-6 hours to install and about $30 in extra tools and parts (I'll explain more later). If you follow my instructions, then installation should be about 2 hours because so much of my time was spent trying to figure what pieces went where, etc.
The tools you'll need to install this kit are:
- Metric and SAE sockets and wrenches
- Circular saw with a STRONG metal cutting blade - I have a Sawzall and figured this would be adequate - BIG MISTAKE. It didn't do squat in terms of cutting through the shaft except break all the teeth off the blade. I ended up using a DeWalt 4.5" grinder which yielded success.
- Center punch
- Hammer
- Electric drill
- Tap handle - for the 3/8" tap. Do not use a wrench to turn the tap. A wrench does not allow you to put equal force on both sides of the tap like a handle does and therefore you can easily break it off inside the shaft.
- 1/8" and 5/16" drill bits
- 3/8" and 5/16" allen wrenches
- Cutting oil - I used WD40. I'm not sure if it qualifies or works the same as cutting oil, but I didn't have any problems with it.
- Silicone sealant - I used VersaChem Automotive Black RTV Silicone Type 270. This is the best kind of RTV sealant I've used. It comes out of the tube easily and is soft which allows it to be spread over a surface by hand.
- Loc-Tite - for reinstalling important nuts and bolts with assurance that they'll stay tight.
As per the installation instructions that came with this kit, the contents should have been as follows
(1) - Bearing/Seal Flange
(3) - Grade 8 M10 x 25mm Bolts
(1) - Seal
(1) - CV Output Flange
(1) - Yoke Strap kit
(1) - 3/8" -24 Grade 5 Bolt and Washer
(1) - 3/8" -24 Drill and Tap kit
(4) - 3/8" -16 CV Nuts and Bolts
)
However, this kit came with the following (photo clockwise from upper left):
(1) - CV Output Flange
(1) - Bearing/Seal Flange
(1) - Spicer U-joint yoke strap kit
(1) - Seal
(1) - 7/16" -24 Grade 5 Bolt and Washer
(5) - 7/16" Lock-washers
(3) - Grade 8 M10 x 25mm Bolts
(4) - Grade 8 Bolts (similar to the 3 bolts listed above, but a little larger - not sure what size)
(1) - 3/8" - 24 Tap
The advantages of using this kit are simple: it's cheap ($199 USD), easy to install (done while the transfer case is in the vehicle), improves your lifted vehicle's rear driveline angle, and allows a lowered transfer case to be put back into it's stock location.
