Quote:
Originally Posted by dville
You do NOT have to take of transfer case to remove front driveshaft.
I just did it (I have BMW TIS CD).
The reason the splines on the transfer case have so much extra room is so you can remove the front driveshaft.
You simply remove the front stiffener plate, undo the bolts at the front driveshaft flexdisk, then use a crowbar and slide the shaft backwards until the flexdisc can slide out (it has a centering device that sticks into the flange on the front differential preventing it from just dropping out).
If you lengthen the front driveshaft, then you will HAVE to remove the transfer case to take out the front driveshaft, since you will not be able to slide the shaft backwards to clear the flexdisk.
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I see that now, due to living in the middle of the "rust belt", it appeared that the pilot flange and the shaft were one piece. Working on it at 3am didn't help either, I just wanted to get it apart. The first prototype I put in my own car was a little longer than the new production pieces, so I had to remove the case. As ttzcar just posted, the new extended shaft goes in with out having to completely remove the case. I would like to give a big thanks to Joe and Jimmy for being so patient during getting these made, we ran into a few bumps but it looks like smooth sailing ahead. I have some pictures to upload of the new shafts, I'll get them up shortly.