UPDATE,

Ok guys I finally decided that the problem seems to be from the front of the driveline. It has however raised a few more questions.

When I unbolted the bell housing at the front of the torque tube and slid it back I found that there was very little oil ( maybe only 50mls )I seem to remember that the housing needs to be filled with a half pint (300mls)of trans fluid when its put back together. Never had any problem with a high oil level in the diff. Just wondering that when the PO built this maybe he forgot to fill the housing?

Three of the four cap bolts on the u-joint front yoke were loose ( its just as well the lock tabs had been installed. There is a little bit of sideways movement between the trunnion and each of the four trunnion bearings with some discolouration on the trunnion shafts. How much play is acceptable?

There is also noticable play on the splined drive shaft. Could it be time to remove the bushing and instal an okie bushing?

Any other jobs that I should be looking to do while I've got the TT disconnected?

Sorry for all the questions guys but its the first time I've worked on a TT driveline. It's another in a growing list of jobs that I've done over the last few months that I wasn't expecting to have to do. This truck has supposed to have had a complete rebuild.

Anyway as always I'd appreciate your input.

All the best

Bob