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I developed a driveline vibration when I installed a set of new 4.11 gears in my '55. The 9" diff is originally out of a'70 F100. This is the first rearend I have set up. I have what feels like a loose yoke or bad u joint feel that starts about 60 mph and really gets noticable above 70 mph.
Things I know it is not:
driveshaft or u-joints (replaced)
rear bearing in tranny (Tremec TKO)
pinion/tranny angle
rear yoke
engine or tranny mounts
I can pull the axles and it is still there.
The rearend setup well and backlash was to spec. Tension was put on the carrier bearings to Ford manual spec. Yoke torqued to spec. (kit had solid "crush sleeve" with shims) Pattern looked good. There was no glitter in the the oil sample I looked at after about 2k miles. There is no up and down or in and out pinion movement detectable with a dial indicator.
The pinion bearings fit a lot tighter on the pinion than the factory ones. I measured the old crush sleeve and used the solid one and shims to match. Pinion rotating torque looked good although I did not have a torque wrench that would go down low enough in inch pounds.
I think you may have already stated your problem - "I developed a driveline vibration" Even though you have a new shaft and joints I think you still have a problem here. Either the new shaft needs to be rebalanced, something is mounted off center or maybe a u-joint is bound up. The other thing to maybe watch for because it has a large arm, or length from center of rotation, are the balance and mounting of the rear tires. I wonder if a dial indicator would help determine problems with the drive shaft?
P.S. How about some pictures of your '78 project...
'78 F250 4x4 Supercab Camper Special. Cummins 6BTA, NV4500, South Bend clutch, NP205, Dana 70/60. Project
Sounds very interesting. I am trying to convert my 400 C6 NP205 to a Ranger torque splitter - NP435 - married twin stick NP205 with HD Dana 44 front and 60 back both with selectable lockers (not sure which ones yet). My progress is slow and money based but still moving along...
The old driveshaft had a bit of bow in it and was replaced with a new d/s built by a reputable local company. Both u joints were replaced during the search to find the vibration. Every problem I have addressed has reduced the vibration slightly, but has not fixed the main problem.
The vibration is there without the axles installed.
See if the slip yoke (female) is deep enough for the driveshaft (male), it might be bottoming out and not have enough room to compress. Which might be why the other one bent.
I am having the same problem with my 95 4x4. had rear gears changed to lower set. Broke them in as directed, and now at 55 to 70 mph i get this terrible vibration in the drive line somewhere. But I also can't seem to be able to put enough transmission fluid in it to keep it full. I have a leak now that I didn't have before the new gears?? Any suggestions on what could have caused this, or what it is?
The truck is sitting at the place the gears were changed, and will be talking with them tomorrow. Hopefully they will fix the problem that they have created!!!