I've never had to pull a broken driveshaft out of one of these cases. I was wondering, is whole slip yoke splined? If not, couldn't you find an appropriatly sized rubber stopper for the hole and some extra fluid to keep from bleeding to death on the trail? Or is there some case pressure that would push the stopper out?

yes the rear shaft is splined. What you can do is take a plastic 12 oz. beverage container and cut the top off and duck tape it onto the tailhousing keeping the fluid in. (I've done it). Another way would be to take the vehicle and park it going downhill or jack the rear up then pull the shaft out and take the slip yoke piece off and put it back in checking occasionally as you limp off the trail. DO NOT DRIVE DOWN HIGHWAY!!!

I've looked at this some more. The slip body (female) slips over the splined transfer case output shaft (male & splined for her pleasure). The slip body is not splined and has a diameter of 1 7/8". With this knowledge, you should be able to stuff the hole with a 1 3/4" cork stopper tapered to 1 15/16" to prevent from bleeding to death (a little duct tape to keep it from slipping out). Does the output shaft stick out of the slip yoke body at all? Diameter of output shaft? I'm thinking it would still work if you need to drill the center of the cork a little for output shaft clearance. Input guys? I would break the thing open, but I'd rather not if I can.

The slip output shaft does stick out a couple inches of the transfer case. The diameter matters on which unit you have, the 27 spline 1/ ton or the 3/4-1 ton 32 spine unit.

A couple of inches isn't good. I'd need to do a little engineering on the cork concept. It almost seems worth upgrading to the SYE and 32 spline output for the future anyway. Fun little project too. Have a lot of people snapped the 27 spline output?

I've never heard of anybody breaking the output shaft on one of these cases. For breaking a driveshaft, you can always get a junkyard replacement shaft for cheap to carry as a spare (I've bought 2 for a total of maybe $50).

On my 241 the output shaft is probably close to, or maybe slightly sticks out past the seal. It's pretty easy to just tape a rag around the opening or a cut off pop bottle just to slow down the fluid leak (not like it pours out anyway). Drive it home and just check it every once in awhile to make sure the fluid level is okay.

I just realized I had the image of the output shaft without slip yoke cone attached from doing my SYE. With the cone on the end of the shaft is close to the seal, but protrudes maybe less than an inch.

here's a couple plugs i found on the net.

http://www.speedwaymotors.com/xq/aspx/display_id.1948/qx/product.htm
http://www.midwestmotorsportsinc.com/order_part.php?item=41060&line=MOR

I've used something similar to these in my 241 numerous times.