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Anyone running an aluminum drive shaft. Considering one. I think the last person I let work on my truck forced the wrong Ujoint into the rear drive shatt. Vibration starting about 60mph. I've eliminated everything I can think of but it so here we go (hopefuflly not down the rabbit hole.) Going to replace the entire drive shaft as I'm very tired of chasing this problem.
Most salvage yards have a bunch of used drive shafts usually inside of an old school bus or truck body. With a tape measure you can sort through the pile and find what you need. You might find an aluminum shaft in the correct length with the right U joints to work in your application. I don't see any real reason to get tricky with a driveshaft.
My friend Wes ran 5.70's in the 1/8th in his Ford pickup for hundreds of passes with a driveshaft made with one end from a Caprice and the other from an Astro Van. He tried a fancy chrome moly driveshaft and wadded it up in 2 passes. Your mileage may vary...
I would see if you have a driveline/driveshaft shop locally... a few yrs ago, my Excursion decided to spit the d/s out after a gear change (long story, in the Ex forums) got used Excursion one, had it balanced, still had vibration, new u-joints, everything checked out saying it should be fine, older mech, (the owner of the shop actually) suggested we lengthen it 2" and get it seated further in the transmission, lengthened it, rebalanced, badda boom, badda bing, smooth as can be. All that to say, are you sure all your insertion lengths are solid as is your slip yoke..?
PEM in St Clair MO does custom driveshafts of all types. I had them shorten and rebalance the driveshaft in my truck when I switched from a C6 to an E4OD.
At one time there were three good driveline shops in town. Now the front of one looks like a taco shop and I never heard of them. The other is an old shed building with a broken down cement mixer and a dump truck taking up all the lot.
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