Problem is I dont have a welder.

 

Know anyone with one? Or go to home depot and by yourself a stick welder for $2xx

 

Hell I just heated em beat mine with a baby sledge n used a floorjack to push my old springs down I'm fabricating. My own lift 4 shackles. N rear and Pontiac. Catalina. Springs on 3 inch lift cups all my lift costed 45$ rides descent. Next question is the steering. And now im goin to fab a 2 inch transfer case drop I want it sitting high with no driveline issues

 

file two sides flat and get some vice grips on the *****, and heat it up red hot before trying to extract it.

 

This is a great thread. I am expecting some problems converting my 2WD '98 over to 4WD and I believe you have touched on every problem. As many old cars as I've built, PB Blaster and a whole lotta a$$ has removed 90% of the bolts. An additional 8% broke, and the other 2% were pounded, cut, smashed to oblivion, heated, or otherwise disected from their resting place in a most brutal manner.

 

PB blaster wont do anything except give you a false sense of security when your bolt gets frozen in your bushing. I used it for WEEKS leading up to doing mine, and even backed them out a bit to make sure they werent frozen. Gave me a false sense of security and I ran into a lot more trouble because of it. Read my write up!!!!!

 

My welded nut didnt break... the bolt did..
And if I cut that area out I cant weld a peice back over it because I dont have a welder.

The only welder I could borrow is way out of my skill level.

 

I know, thats what happened to me. Thats what Im saying.

 

Drill out and improvise

 

no one makes a full SYE(where you replace the output shaft entirely) for the 242, your only option is a hack n tap. basically you cut a portion of the tcase output shaft off(being as straight a cut as possible) and then drill and tap a hole in the center of it(again, being as straight as you can). then you bolt on a new yoke to the existing output shaft. they are not as strong as the full SYEs but there are loads of people who have done it and honestly i never hear anything bad about them.

and on the upside they are cheaper:
http://www.ironrockoffroad.com/Merch...egory_Code=XDT

$200 for everything you need.

i would suggest you measure you front driveshaft to make sure it will be about them length you need(this kit comes with a refurb stock front xj shaft). i have an AA SYE and a front DS would be about 4" too short, but then i have a manual with the np231 and a d35(for now). i have heard of many people running front DS on the rear with no issues.

 

It is true that no one makes a HD Sye for a 242, but Tom Woods comes pretty damn close...
http://www.4xshaft.com/SYE/242LateDe...e27spline.html

 

that's the same as a hack n tap, just done in a machine shop. i wouldn't be able to justify another $270 plus a $400 core charge for essentially the same thing as a hack n tap minus labour. i know tom woods is well regarded and they mod the shaft in more ways than just cutting and tapping, but strength wise it is just the same.