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I cut an appropriately sized hole for the tail shaft of the
transmission in a piece of stiff cardboard. I shoved a marker in one of the
holes from the back and ran the cardboard by it. This gave me the diameter. I
poked a hole in the cardboard at a point along the line and placed the tip of
the marker through.
I ran the marker in a circle around the back of the
transmission. I measured the distance from the edge of the existing hole
to the punch mark very precisely.
I used a punch at the place I wanted the new hole. I used
that measurement to place a punch mark in the exact same place next to every
existing hole. I drilled an 1/8� pilot hole and rechecked my measurements.
I then drilled them to 7/16".
I slid the transfer case back on and bolted it down. Perfect fit.
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