80 series tranfer case flange

[Flashman_28]

Hi

I have come across a problem with putting my modifed drive shaft back in to my 1997 80 series, it is a 40th annin 4.5 petrol auto.
Since i have had a new drive shaft made up from my old front drive
shaft and a hilux double cardin ( i realised this before starting )
that the hilux plate on the end of the double cardin is different in its hole pattern to the standard lancruiser tranfer case flange studs. So i have had to grind off the studs that were on the tranfer case flange and drill holes for the new bolts to line up with the hilux hole ( the centre of the
flange is a perfect fit to the centre of the hulx plate on the double cardin).

But, and here is the pain, there is a plate behind the flange in the transfer case end which they call in some manuals, a protector plate, which is stopping me getting the nut and split washer in to bolt up to, and there is no way i can get a bolt in from behind and put a nut in from the other
end.

Has any one else come across this problem? how did you get around it?
Is the protector plate removable? Is it important ( some one at toyota must have thought so. Is it possible to remove it without dropping the transfer case and putting it apart?

Chris

[5link80]

I have had this problem on a zook before.. Why no try drilling a hole in the flange and tapping a thread into it.. There is a good 6mm on the flange which would be enough for a drive shaft..

Kyle

[Flashman_28]

thanks Kyle

Tried tapping the holes but as it is a bit of a nightmare to get the flange off, it has been a little too inacurate to get the holes to line up perfectly and it is giving a problem bolting it through to get the threads to line up. Great advice though.
I am probably going to just drill the holes out and grind a chamfer on the nut and slide it in between the flange and the seal protector and bolt up to that.

Thanks

Chris

[M&M Custom Engineerin]

What is so hard about pulling the flange off?

Just pull it off and do it properly, the last thing you want is a bloody driveshaft falling off

[RUFF]

Ask Nick about how it feels when the front of the rear tailshaft falls out at 100klm on the highway and what the underside of his rig now looks like
This happened to him yesterday.

[Flashman_28]

I am getting a bit out of my mechanical depth already chopping up drive shatfts, dropping the transfer case and finding out how to get the flang off doesnt sound like a weekend mechanics job!
I have to admit i dont want the damn thing falling off, what sort of mess did it make?
Is there a new textured floorwell finish to go with it ? ?

chris