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Discussion Starter · #1 ·
Im trying to diagnose vibes, but I have to leave in about 20 minutes! I got all 8 bolts off the front and back, disconnected the front, but how the hell does the shaft disconnect from the transfer case? Its stuck solid!

Well, disregard. Got it off. Just to confirm, I'm not hurting anything keeping it off correct? If this quiets down the vibes, I may keep it off till I can get it rebuilt, just want to make sure I'm not messing anything up.
 

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Won’t hurt anything to drive it without the front drive shaft.
 
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Discussion Starter · #3 ·
Guess either a rebuild or a new front driveshaft is in my future. Smooth as a baby's butt all the way up to 75 with the shaft out. :(
 

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Good thing you pay attention to changes, unlike others who find out with an explosion of destruction under their feet.
 

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I just recently replaced my front DL. The local shops said that they build new ones for the cost of rebuilding the old one. I think it was just north of $500 for a new Tom Woods DL.

You can replace those Torx 40 bolts with some M8-1.25X40 metric class 10.9 Hex flange bolts when you put it back together.
 

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You can rebuild that cardan joint in an hour if you take your time. They aren't hard, just make sure you grease the spring and ball between the joints or have a driveshaft built without the cardan joint and notch the trans support to clear.
 

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I replaced my driveshaft in lieu of the ujoints, price and convenience were there for me vs rebuild. I also did the bolts too.
 
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Yes, universals are greasy hard work, throwing a new driveshaft in is way easier if you have the money. The u-joints start at $10 though, if you're so inclined to do it yourself.
I have replaced plenty of U-joints but those relevant to the Cardan joint is what I wanted professional experience tackling. The last thing I want is that front DL wiping out my trans while towing my 5er.
I thought it was pretty interesting that the shop said that the cost to rebuild would be "sixes" to buying a new one from them.

Sidenote: My 04.5 did NOT have any grease access in the Cardan joint as verified when I removed it and the shop that measured it for the new one.
 

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I bought a new front DS as rebuilding wasn’t really that much different and I was t sure I had the skills to rebuild it correctly. Mines an 05 so don’t feel too bad it lasted until mid 2020!


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