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Brand new adjustable trackbar and bushings got installed with the new suspension.. Bolt had to be torqued to almost 400ft/lb.... Today I reinstalled the front driveshaft and locked the front hubs removed the rear driveshaft and put it in 4wheel drive, vibration is gone, I am going to drop my drive shaft off and get it checked at the local diesel driveline shop. It's just so weird that the vibration in the steering wheel was able to travel up through the tcase, trans and engine through the steeringwheel! I guess ill see what the driveshaft people say, the rear pinion felt good when i jerked around on it.
I just got done having the same issue. Check pinion angle, which was not the issue in my case. My problem was the drive shaft. Had it balanced 4 times and was told it was good. Turns out a drive shaft can balance out and be fine with no load on it. Add a load and well you start to have issues. So I had it re-tubed and the stub replaced on the slip joint. If you have any play in your slip at all, have it replaced. Total cost for repair was 230 which included new u joints.
Before I got to your post about removing the rear driveshaft, I was going to guess that was the root cause. My 2003 vibrated from new (not as bad as yours though). Finally, I had new u-joints installed along with a driveshaft balance on the 2003 one piece unit. All vibes went away.
Conclusion--even with correct pinion angles, the u-joints and driveshaft balance can cause this sort of problem.
My 2005 has very very mild vibes at 80+ mph. I may take this two piece driveshaft in for balance and new u-joints now that it has over 120,000 miles on it...
There is other threads too, like Sammies', do a search.
I have several out there on the vibration issues, and a good deal of my issues and their resolution (which was pinion angle) are mixed into the thread that Atc210 mentioned below. Pinion was the cause of my high speed vibration, I have more than one and the lower speed is still pending.
PROBLEM FIXED! Rear Drive Shaft Had a bad U-joint and was out of balance. AHHHHHH!!! Smooth Sailing!!! Was really weird that the vibration was coming from the rear driveshaft but yet sitting in the driver seat I'd swear it was coming from the front end.
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