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Old 11-21-2021, 08:55 PM   #11
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Update:
Have been at a junk yard today and checked some other RWD vans and trucks. All of them had some play on the slip yoke, partially more partially less than mine. So I took my chances:
took out an extension housing + slip yoke and brought it home.

Although I just changed my bushing the slip yoke I got from the junk yard had much less play.

So I installed the new slip yoke into the current ext. housing and put a new u joint in (front, Spicer greaseable) and the noise changed significantly. I can now drive >70 without that rattle and the vibrations while decelerating reduced a lot! But there‘s still „some“ noise.
Looks like the yoke/ bushing play is more important than I thought.

Will now replace the rear driveshaft u joint and check again. Then tire roration and check.

If still some noise I check the rear hub bearings and in case that‘s not successful I go back to my diff/ pinion.
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Old 11-21-2021, 10:39 PM   #12
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Glad to hear (no pun) your making progress.
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Old 11-22-2021, 09:33 PM   #13
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Soooo… did some more work: replaced the rear u joint and found the diff has some degree of free tilt. Once I find out how and where to upload a video I do so.

BUT: found something else.

I replaced my slip yoke with the one I got from the junk yard and now checked my old one again. I see scratches on the first ~25mm corresponding to the 25mm in my old extension housing bushing (copper layer was already fully gone in that area).
The other problem is that the bushing itself is ~40mm. Means I‘m missing at least 0.5“ in length after my 3“ rear lift. That means I don‘t have the designed „bearing area“ + I only transfer torque on 2/3 of the area!






So if I don‘t solve this permanently I guess I will have to do it again and again.

My idea is to get a driveshaft spacer. Axle relocation plates will not really provide the movement I need.

Anyone an idea where to get a 3/4“ spacer?
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Old 11-23-2021, 02:13 PM   #14
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You mean like this?

https://superlift.com/product-detail/4310
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Old 11-23-2021, 02:38 PM   #15
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Yes, "LIKE this". The one shown seems to be for Chevy/ GMC.

I found this one at 4WP, but still got to find our more about the dimensions. As this part would also center the driveshaft via the small collar it needs to fit my diff.

https://www.4wheelparts.com/p/fabtec...S92003#qstnAns
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Old 11-24-2021, 06:58 AM   #16
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Have you verified the driveline pinion angle? J-Sweezy found this to be the root of his driveline vibration after he re-did his 4x4. More driveline info here:

https://madocumentupload.marketingas...16fdb&v5=False

A change in pinion angle can also affect effective driveline length.
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Old 12-02-2021, 01:32 PM   #17
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carringb, I will work on the van again on Sunday and put the driveshaft spacer in (in case it fits... not sure yet). I have not checked the angle, but I would be really surprised to see a 3" rear lift not working. I have the feeling it's a fairly common lift and seems no one else has these problems after lifting...

But: let's see. I keep you posted on the progress
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