I have made some progress trying to get ready for the Rising Sun rally. I had a tinted "brow" put on the windshield so you can't see the wiring in the overhead console anymore. I finally got the check engine light to go out. I will not bore you with the details, but it gets way better gas mileage now. I have the new bracket built for the transfer case end of the traction bar ready for painting and will hopefully have the traction bar ready and installed for the new full float rear axle I had previously installed by the rally.
I have had a leak from the front output flange of the transfer case for some time now. I have replaced the seal several times (with Toyota parts) and have speedi-sleaved the flange but it has all been for nothing, because it is leaking quite heavily. I also had to redrill the driveshaft holes in the stock flange when I added the double cardon long spline driveshaft I built. That put the holes on the outer edge of the flange. I have tried to find a new flange but none of the course spline flanges are big enough to add the larger bolt circle for the double cardon joint. So ... I contacted Georg at Valley Hybrids. He has sent me a fine spline front output shaft, heavier duty nose cone, and fine spline flange already drilled for the double cardon joint. Also the Orion transfer case I have occasionally pops out of high range on heavy decelleration, so Georg also sent me a brand new main shaft and main gear bushing to resolve that problem. So monday the tranfercase comes out and the new parts go in. I am excited to get my worst leak fixed! I can't say enough good things about Georg, what a great guy!
Thanks for listening to my ramblings.