Im installing dual cases into my 85 4runner (lifted about 5 inches) and need to modify the shafts. I have a 92 axle in the rear, which i beleive lessens the pinion angle. Will the angle (more worried about the t case end) be ok just using my stock shaft cut down around 6.5 inches shorter? And would lengthening my front stock shaft be ok as well?
Thanks

 

You are going to heave to measure and see:
- http://www.4crawler.com/4x4/ForSale/Shims.shtml#FAQ1

Likely rear alignment will be fine if it was fine before and is still a single cardan style. But you might push it over the edge operating-angle-wise, so to speak. I found once I got into the 12-15 degree range, smooth operation at speed was a thing of the past:
- http://www.4crawler.com/4x4/CheapTri...n-Measurements

I converted mine to a double-cardan setup and now it is fine.

 

In addition to lengthening the front shaft you will want a long spline shaft

 

Ill ask them to do that when I get them done. Im getting a front range offroad crossmember along with the cases, but the reguires to weld on mounts inside the frame rail and I dont trust my little flux core welder to do that. Can i use my stock crossmember for mostly road stuff and possibly a small amount of mild wheeling before i get a larger welder to weld those mounts on? It should be able to bolt on to the first reduction housing, as the adapter and the tcase is behind that. IS there any modding or issues that could go along with it?

Also, whats the name or part # of the gasket that goes between the trans and the transfer case?