Saturday was intermediate shaft morning. Which turned in to intermediate shaft afternoon, then intermediate shaft day, later intermediate shaft night. That turned in to intermediate shaft Sunday afternoon.
Saturday I started about 10am and I planned on having an easy day. Truck came apart easily enough I was in to housing in about an hour and half. The shaft was out of the housing, bearings pressed on the new shaft and the housing reassembled by 1pm and back in the truck by 1:30. After that everything came to a stop. The new CV would not fully fit the new shaft. I thought maybe it was the cer clip but after sever attempts, we placed some paint on the shaft and reattempted. It appeared the shaft was only going on 3/16". By rotating the shaft and clocking the splines I was able to get the depth to 1/4".
Tried taping with a dead blow and it simply got stuck. Took about an hour to get the stuck shaft off the shaft. So I broke out the jewlers files and ran over the splines in an attempt to eliminate any burrs. Tried again and stuck the shaft again and my neighbor and I had to pry and tap the damned thing off again. I tried stoning the shaft, no luck. The OD only varied by .002' So I assumed it was within spec. the shaft splines measured 1.226 to 1.228 within spec. The CV's were harder to measure. SO I went and bought another CV joint. It was even tighter.
I had my answer the replacement shaft was messed up somehow. Put the truck back together without the cv so I could back it out for the night
Sunday about 12:30 new shaft arrives. Test fit in to the CV's, all good. Tear down the truck, do the whole thing all over again. About 4pm I buttoned the truck back up with new brakes, and backed out for a test drive. All went well and the vibration from the passenger side is gone.
I say ALL this just to pass alone these words of advice, test fit replacement parts off the truck before you begin. Save yourself a days worth of work.
