August 7, 2007A few weeks ago I installed my RE hack and tap, a word of caution for anyone installinig one, get a good quality tap from a professional tool distributor before install the size is a 3/8-24 also the drill bit they provide is a POS too. But it was my own fault for not going into my tool box and getting a good tap out.
Anyhow here are a few pics of the madness.
The extension housing removed about to measure the shaft to cut
The shaft measured where to cut and used a hose clamp as a guide to cut and grind the shaft
Shaft cut and ready for final grinding flat
Shaft drilled out and ready to tap(took forever with the supplied drill bit finally used a Snap On Cobalt bit 21/64"
Cutting the final thread with the supplied tap and voila the tap broke trying to remove it
Called it quits after breaking a tap extractor in it
Made a bunch of phone calls and luckily a friend of mine had a spare NP242 main shaft
Did everything I could to not remove my T-case replaced the shaft in the truck
Better pic of the messed up shaft
After 7 hrs in total with dealing with the broken tap and getting the shaft and cutting it on a band saw and drilling it on a drill press
The trouble could have been avoided and I would install another only using better tools, but now there are no driveline vibs in my XJ.