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Recently had a U-joint that was popping on my front driver's side. Replaced the U-joint and popping stopped, but when I make a hard right turn it hops, and in 4wd any right makes it hop.
And you've replaced that u-joint already. I'm pretty heavily leaning toward the CAD housing stuck in the 4WD position, but it should hop turning both ways if that were the case.
just to be clear..."CAD" talking about the housing on the axel toward the passenger side where it engages 4WD. and what do you mean 01 FSM? sorry for the lack of knowledge on the terms here.
Sounds to me like the U-joint is in a bind. If it isn't in straight it will make the caps too tight and the joint won't move freely making a hop. But could also be the Axle disconnect not disconnecting. You are correct that the axle shaft on the passenger side will not seat all the way in if the collar is in the wrong spot. You also will notice that the hub is not seated. The hub is what holds that axle in place. I say pull the CAD and check the collar. Make sure it is disengaged. If you have to take the collar out and seal it back and see if the hop goes away.
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