Chase: Very interested in the shimming of the front motor mounts to lower the rear of the T-Case in order to clear the parking brake/cross member issue. I'm glad that you are paving the way! My one-banana mechanic skills are being sorely tested. :)
Chase: Reading your thread, I believe that you disconnected your parking brake at the firewall for removal of the trans/T-case. This is the approach that I would like to implement as well. Is it pretty self-explanatory, or are there any tips/tricks? I've dealt with the other end of the cable...
Nice work, Chase: Since I'm hot on your heels, so to speak, and following your excellent work closely... Curious on how you will be addressing a few issues: 1) Will you be keeping the hi/lo 4WD shift mechanism under the dash, if so, will you be need to lengthen the linkage rod? 2) Will...
Nice work. Did you pre-fit your new pilot bearing to the shaft? There is some discussion about perhaps using emory cloth to make installation go smoothly.
Chase:
If there is good solid steel surrounding that small hole, you could easily fill it with a mig and grind it smooth. prime and paint. A magnetic copper backer makes for quick work.
If you do decide to replace the axel seals and bearings "while you are in there" remember that the axle has pressed on races (at least ours did). I ended up taking them to a machine shop that could press them off. But it is a nice feeling to go back with new seals and bearings.