So in my search to find the vibration I jacked the truck up in the garage, put the rear diff on some jack stands. I then put the truck into gear....... no this is not where it falls off the stands and drives through the house <img src="/forums/images/graemlins/lol.gif" alt="" />. Anyway the wheels spin true, the driveshaft seams to spin without any sign of vibration, but there does seam to be come clunking coming from the center differential. Now I only had the truck doing 1000 rpm so i was only reading 50 kph but the clunking seamed to be coming from the center diff. I shut the truck off and took it out of gear. I felt for backlash on the input into the diff and there was very little. I would guess I could move the driveshaft back and forth less than an 1/16 of an inch before I saw movement in the tires. Now was the clunking due to the fact that the truck had no resistance to movement? Any other ideas? I guess I will not know till I pull the diff out and have a look inside. Has anyone here rebuilt one of these before?

Have you read this thread? Link

Yes I have read this post and from what I can see I have no discernable wear on the splines and the are engaged most of the way. The part that intrigues me is the part about having the rear of the transfer case off and getting a new bushing installed. I am wondering if this is my issue. I just had the driveshaft balanced and the vibes are less but they are still pronounced. I am hoping to go to Vancouver next week, but with the vibes I am having I don't want to take it. It would be real nice if one of you could go out under your paj and push up and down on your driveshaft where it enters the transfer case. I get about 1/16th of an inch up and down and side to side play before the transfer case starts to move. Is this normal or to much movement?

If I had a garage I'd do it for you now. Hope someone comes through.

No, sounds like you have a worn slip shaft coupler. Should be tight with no discernible motion up/down or side to side.

Unless the whole output shaft is moving. I will remove the tailshaft housing and check it out. Any idea if it is possible to get the slip shaft if it is worn?

Yup slip shaft coupler is worn, any idea on parts availability? Is the output shaft harder than the driveshaft part? Hopefully I can just change the driveshaft part...... There is also a bushing in the tailshaft housing. The sleeve and the bushing are 0.010" different in size. There are no wear marks on the sleeve. So the bushing is worn as well. The bushing will be a mitsubishi item only I think, as it has helical grooves on the inside for oil.