Everything is tight. Just checked it. After reading ypur "Driveline 101" I have come to the conslusion that the front and rear angles are pretty much in line with each other and are equal. From reading your stuff, I see that 1-2 degrees lower in the rear is preferred. I have 6 degree shims on there right now. So I guess maybe I need 5 degree shims to lower the rear angle? Am I thinking right on this? It is almost tolerable noise right now so I probably shouldn't go all the way to 4 degree shims I am thinking. Let me know what you think and I'll order some from you.

Yes, you generally want the pinion angle to be 1-2 degrees below that of the transfer case output flange to allow for uptilt under load.

Although since you are having trouble at no load/coasting, that may not be the problem.

You may also have just put the overall driveshaft angle beyond it's limit with u-joints. I found on my '85 that happened when the shaft hit someplace in the 12-15 degree slope range (about 4" lift and shortened shaft with dual cases). Nothing would make it run smooth until I had a CV joint put on the top end and rolled the pinion angle up to align with the shaft.

I meant to say 5 degree shims to raise the angle. Does this sound right to you? Does 1 degree make that much difference? I guess so. Thanks again Roger.

If you are saying the pinion is more than 1-2 degrees below the t-case flange, then yes, raising it into that range may help.