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I posted about this many moon ago here: https://www.ford-trucks.com/forums/8...ml#post9031839
(I was CorkyNM then, but my account broke and I re-registered as CorkyNM2)
I have scraped off much of the blue teflon (or whatever the thick hard plastic space-age monkey doo is called) Ford painted on the splines, and lubed it up with a quality grease and it has not bumped since. My truck is a 2010 - not sure of your year but maybe it would work for you.
The other alternative is to take your relatively new shaft to a drive shaft and have them rebuild the shaft. I was recently talking with the local Fleet Pride tech. He says hes sees at least one a week. They cut the GD spline off and weld on a fresh spline W/O! the coating. The tech says he hasnt seen one come back yet. Hes been there 15 years. The Ford grease seems to do the trick for my last two 250s
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