Originally Posted by 96 XJ Sport

SYE and DS are in now. It more of a pain than it should have been because I'm a DA and broke the tap off in the tailshaft. My neighbor welded a bolt to the tap and tried to turn it out, but it just broke the tap off deeper in the hole. Here are some pics of the successful parts of the install, lol, followed by the ultimate result of him just welding the flange to the tailshaft. He's a very experienced welder, so I trust it.

I cut the tailshaft with it spinning in reverse (in 2WD of course and the front wheels chocked). I highly recommend that method for a smooth and square cut.


Slid the flange on temporarily to more easily find the center of the shaft to punch it.


This is the final drill with the 21/64" bit included with the RE kit, but I pre-drilled with a 5/64" first and then a 3/16"


Sorry, no pic of the broken tap. Let's just say that I learned how to tap and will do it correctly the next time So we had to go to plan C, welding.