I couple of months ago, I removed my rear drivshaft. When I did, I forgot to mark the holes so I could put it back in the same way. When I pulled it out the yoke seperated and I just stuck it back together. Now when I drive it under load i.e. 4Lo and climbing, the drive shaft flange on the t-case end grinds on the horse shoe that holds the t-case shift linkage.

I am going to take the shaft to a shop and have it balanced because I think that is half the problem. My question is: How do I figure out the original mounting position (matching the original holes together)so I am not causing any damage to the case or the shaft?

 

http://www.4crawler.com/4x4/CheapTri....shtml#Phasing

 

Thanks 4crawler.

 

So I followed the guide given by 4crawler. My joints were, uhhhh, way off parallel. I straightened them out and took it out for a test drive. It didn't grind as much, but it still jumped out of gear, mostly under load when bouncing (I know that is not good, so I try to avoid bouncing.) When I got back, I again looked underneath and saw a large rubber square with a bolt in it.



If you look on this picture there is a bracket where the torsion bars used to be.



There are also several bolt holes in the bottom of the cross member in fromt of the transfer case. My question is: is there supposed to be a support right there under the rubber piece to support the t-case from bouncing? If not, then I am guessing that there is something wrong with the case

 

Not sure what that block is for, maybe some sort of vibration dampener or something. In the upper picture, you can see your t-case mount bolted to the sides of the case, the two shiny bolt heads in at an upward angle. Should be two similar bolts on the opposite side and typically 4 smaller bolts in through the bottom of the cross member to hold the t-case mount down. Check the rubber in that mount for tearing and also check your two motor mounts up front.

 

So I checked the mounts under the transmission (motor mounts are brand new with about 5 hours of light off road use on em' so I figured those are good). I dropped the crossmember and removed the mount from the t-case. It felt a little sloppy, and I did see some cracking around the outer edge. I removed the large bolt in the middle and this is what I got:



Gonna buy a new one tonight and see if that helps stop the t-case from slipping out of gear and bouncing.