Used MAP gas and heated up the center until the plastic holding it together melted and burned out. Warning: The fumes from the plastic burning is highly toxic. I used a charcoal respirator during this process.
Once the plastic stopped oozing out and burned off, I simply pulled them apart, and cleaned them off with a hand file. They are close to a foot long each. Put back together, it collapses fully and total end to end length is 16".
The stock Ex shaft extends to 13", and the body lift extension adds another 1.5" to it, for a total of 14.5", with a good 6" of collapse in case of a front impact. This space is needed so the steering wheel/column is not forced into your body in a head on impact.
So... I am going to make this XJ shaft able to extend to 14.5", and have as much room to collapse as possible without losing too much inner shaft. I want as much inner as I can for strength, but the stock set up only had 1.5" inner shaft inside the outer. I would like to have at least 2"' of inner inserted.
Edit:
Got it installed. Cut off 2.5" on the tube shaft, and 3.5" on the solid shaft. Since this has the 3" Body lift, and been using the steering extension, I made this shaft a little longer then one would need for a stock set up. Overall length for the lift is only 1.5" longer then the fully extended (13") stock shaft, not 3". Total is 14.5" installed with a 2.5" collapse in case of a front impact.
All went smooth for the top install. I ground off a little on the steering column stub to allow the stock bolt on the shaft to pass over and clamp it tight. I drilled holes and inserted a pass thru bolt like stock uses for safety.
Bottom end was not so good. The design of the Jeep shaft has the clamp bolt all the way at the end. The Ex gearbox spline shaft stub has the bolt groove in the center, not allowing the shaft to install all the way using this slot. So... there is a flat spot on the box stub like a "D" shape. Turning the shaft to allow it to be on all the way, and be able to slip the clamp bolt on, makes for a sad steering wheel. it is a full 90* out to the right. If I spun one half of the jeep shaft 1/2 turn, it would be 90* off still.
So this cheap $10 mod is not as cheap as it seems, I have to go get an alignment. The pitman arm is keyed, so the only recourse is to adjust the TRE's to get the wheel back to center. Add $80 to the cost of this mod.
Good news is the steering has never been as tight/responsive/smooth, as it is now. Turn the wheel, the tires move, period. Zero slop in it.
Pics:
XJ shaft separated
XJ shaft fully collapsed (uncut)
XJ shaft top end inside view showing bolt in the way
Steering column ground for bolt clearance
Stock shaft with body lift extension & modified XJ shaft comparison. Both at 14.5".
XJ shaft on, upper
