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So I went to pull the driveshaft out to repair the leak coming from inside the slip yoke. I notice the nuts at the yoke on the differential weren't especially tight. When I removed the U-bolts the caps came off the u-joint quite easily, as the needle bearings had been pounded into paste. The joint was well lubed, but the bearings were shot. The ones on the driveshaft side were just fine, no damage. Also, when I attempted to push the d/s forward to clear the rear yoke, it would only move about 1/2" and stop. After some screwing around with it, I got it out of the rear yoke and pulled it out of the transmission.
Upon inspection, I found that the internal splines of the T5 slip yoke I got off eBay had twisted a few thousandths just beyond where the output shaft ends. That's why it wouldn't move forward. Nice soft Chinese steel......... but it was a good price...... I now have a new Spicer slip yoke on order, along with a new Spicer u-joint.
Can't figure on the bearing failures - I never had any vibration issues at all with the driveshaft. Always really smooth. Go figger........
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Any chance there was insufficient forward travel of the drive shaft to cause the rear yoke joint to become the weak link, crushing the needle bearings?
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Yeah. As part of my job (new product design engineer) I have found that in general, the Chinese factories have not figured out how to do hardening. They'll claim they can, but their nominal harnesses are off and their standard deviations through a production run are ridiculous, to say nothing when they do non-consecutive production runs that require re-setting up the machines. And don't even get started into their comprehension of case hardening...
If you have any steel where the hardness is critical, stay away.
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When I had the driveshaft modified, I had it set up for about 1" of forward movement or forward freeplay to compensate for rearend forward movement. The slip joint splines go the full length, and you can see the twist begin about 1" from the aft end of the splines. There are marks on the splines denoting where the end of the output shaft ends during full travel into the slip joint. They aren't very deep, and may have come from me trying to force the driveshaft forward in my attempts to clear the rear u-joint from the rear yoke so I could remove it. I would think that if the twisted splines would have acted as a stop for forward movement of the driveshaft during rearend movement, that they would have shown a lot more damage.
Anyway, I have a new Spicer slip joint (Made in Mexico) on the way, and also a new Spicer rear u-joint. I should have it back together next weekend, and we'll see what happens then........
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