any final thoughts? (should i rotate/rebolt the driveshaft or just change the U-Joint?)
Removing the driveshaft flange or the U-bolts and reattaching it in a different position makes no difference.
Having the
U-joints on both ends of the same shaft lined up with each other makes all the difference. If you had a good shaft and both ends are welded on then you couldn't have messed that up.
If you have a slip joint in the shaft or a spline of some sort between the two U-joints there is a chance you slipped it together in the wrong position.
The Spicer manuals in the the tech tip explain why this orientation is important (and the few occasions when a different angle is advisable).
So far from your description sounds like you have a bad U-joint, it's easy to do.. We've all probably done it at least once.
Do you have a picture of the shaft?
Grigg
