*Pre Installation notes*
| This may effect some of you so this is just a heads up, the picture here is the new HD output shaft and a stock one completely assembled, as you can see the HD one is about 3/4 to 1 inch longer then the stock one, so you may need to cut your rear drive shaft down. This costs about 50 dollars at your local driveline place. | |
Tools Needed
| 1. 1/2 Drive ratchet and socket set | 5. Race driver or something like |
| 2. 7/16, 1/2, 9/16 and 5/8's Wenches | 6. A Press or some 2 inch round tube |
| 3. Seal ripper or a Large screwdriver | 7. Vaseline |
| 4. Hammer | 8. RTV |
| To start, open up your box and make sure you have all your parts there. You should have 1 yoke, 1 nut, 2 bearings and races, 1 seal, 1 output shaft, I speedo drive gear, shims and, 1 housing gasket. |  |
| Begin by Blocking the wheels and removing the rear Drive shaft, Next use a 1 1/8 inch socket to remove the center nut in the center of the yoke. |  |
| Tap the sides of the yoke and the tip of the output shaft softly with a hammer to loosen it up so you can remove it. |  |
| Next take a seal ripper or a large screw driver and pry the seal out of the housing. |  |
| Remove the 5 bolts from the housing and 1 bolt for the speedo cable. |  |
| Tap the sides of the housing to free up it up with a hammer, you may also need to use a screw driver to pry it off the T-case to brake gasket seal. |  |
| Make sure your T-case is in neutral and
your transmission is in gear, this is the best way to not
loose the 13 needle bearings and lock the shift color in
place. Tilt the yoke end of the output shaft down and
slowly remove the assembly, once it is out count the
needle bearings to make sure they are all there. (If you did loose one, drop the inspection cover on the T-case and go after it) |
  |
| Tap the threaded end of the output shaft with a hammer and the shaft will drop out of the bottom of the housing, you can set you old one shaft to the side. |  |
| Next using a Brass drift or carefully using a screwdriver tap you old races out of the housing. |   |
| You can now use a race driver and a hammer to drive the race in. I used the old bearing, a socket and my press to seat the races, I do this just because the press makes it go in straight the first time. |   |
| Make sure your races have fully seated down. |   |
| Next I used a press to remove the old bearing on the old shaft to see how may shims I had on there, you do not need a press, some 2 inch round tube and a hammer can be used as well (done many time on the trail, it turns out I had 3 shims. |  |
| Next Press the new inner bearing onto the shaft, again a piece of round tube can be used for this if a press is not available, just be careful. |  |
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