Has anyone spent any time pondering this? I am going to take a t-case and a sammi yoke down to the machine shop and see what he can do for me. I want to be able to run the sammi rear axle disconnect. Any thoughts or ideas would be appreaciated. I talked to Brent Bradshaw because I know he has done one for the front but I'm still not sure why he hasn't done one for the rear. Thanks! Jake

This is borrowed from the Zuwharrie BBS, which I believe was originally borrowed from this site: The pics are gone now

How to make a SYE   


by: Marshall "mesjr2004"

Post has been edited for clarity and content.

    Once you modify your IFS type Suzuki vehicle for long travel suspension or a solid axle swap drive shaft travel becomes a BIG issue.  The factory drive shaft slips into the transfer case with a slip yoke and has limited travel before it simply runs out of legnth and falls out.   The solution is to run a new style drive shaft that mounts solid to the transfercase output shaft and has the slip section made into the drive shaft, where it can be made longer.  To use this type of shaft you first need to convert the transfercase to a flanged out put type using a SYE (Slip yoke eliminator).   

This flanged output (SYE) was made by Marshall "mesjr2004" and is the first I have seen produced for a Suzuki type vehicle and none are currently marketed for sale. 
His discussion about their creation was centralized on the the Zukiwold website www.zukiworld.com     

Below are pictures and a short description of the process Marshall used.

The SYE flanged yoke was created using a factory Suzuki splined output shaft and a piece of 3/8" plate.  This plate was then boared and an additional smaller plate welded into the back of the center hole to use as a flush mounting surface for the Shaft/Flange/Stud/Nut connection.  Next we welded to the modified flange to the splined output yoke.  We then parted and faced off on both sides before drilling the (4) drive shaft flange holes.
 
The hole in the output shaft had to be boared out with carbide tipped boaring bar because of the case hardening.  The hole is .3320, or really close and .9 deep.   We made a relief cut around the outside of the hole to just over .3750 and .1 deep to remove the case hardening away from the tap.  I really didn't want a broken tap .
We tapped the output shaft hole to 3/8-24. 
I used a stud on the output shaft and secure the stud with locktite.  This adds greater strength and makes removal a simple procedure as the nut and threads will be outside of the tranny tail shaft.  The studs in the Picture are 3/8"-24x3/8"-16,with 3/8 nylocks 

Thanks! I don't know why I didn't think of using the drvieshaft for the splined part! That is very simple!
Thanks again, jake

a samurai T-case flange has the same spline count and slides right on to the tracker T-case output...

Is that the coarse spline one or the fine?
I may just do the swap front are rear on the tracker case. The front on mine is fine spline and the rear is coarse.
Thanks for the help guys! Jake