ok i don't have a toy d/shaft to visually look so i need alittle help. when we did the waggy dana44 swap under a buddys zuk we used the 1310 jeep size d/shft joint on the d44 end and used a sami u-joint at the x-case end of the shaft. well it seems the sami u-joint is the weak link in the d/train. a couple have been broken and we are looking to run something stronger. how do the toy d/shafts bolt up to the sami flange? can you just put it up clock it a bit and redrill it or is it too big? what i am wanting to do is keep the 1310 on the d44 side and replace the sami joint with a toy joint. any help is appreciated.

From my understanding the zuk t-case flange has to be turned down .005" on the center section to accept a toy shaft then clock it 90deg. and it should work

There's more than 5mill difference in pilots! I used an old sami drive line spacer for an adapter at one time. Just thinned the spacer and bored it for the Toy pilot. Then clock and drill the flage. That way you can go back to a sami u-joint for your spare shaft or whatever. You may also find you want the weak u-joint in there as a fuse. I carry spare drive shafts, they are much easier to carrying and change than a t-case.... :)

What kind of motor and t-case gears is he running? This is first time I've herd of someone breaking the sami joints (or were they aftermarket joints).

Here's a little more info. Rockford makes Toy flanges and a 1310 flange if you want to go Spicer both ends... Here's the specs on both:

http://www.rockforddriveline.com/flangedstyle1.htm

Originally posted by Rockrat
From my understanding the zuk t-case flange has to be turned down .005" on the center section to accept a toy shaft then clock it 90deg. and it should work

Yeah, I'd say it's a little more like 1/32 ( 0.03"). The difference in diameter's is closer to 1/16". I don't remember what the exact figure was when I did mine. But you get the idea. If you have the larger Sami flange, it helps but you can make it work with the earlier one.

do you have to modify both flanges (pinion and t-case) or just the t-case for the toy swap. i scatter sami u-joints regularly and i destroy the end yokes in the frickin process. i am sick of my junk breaking too!! fill me in i am very interested in the d-44 swap too. BROTHERS UNITE LET US FIX THIS PROBLEM!!!:rasta: :smokin: :rasta:

Which year sami's have the larger pinion flanges and t-case flange :D

i *believe* it's the 88 1/2 model years and up? but don't quote me.
please, never quote me:D