Let's see if I can recall events over the past 3 years,
1. Re-geared the rear axle with Motive 4.56 gears, replaced the right rear axle bearing/seal as the seal was leaking, and installed new Yukon clutches in the Traclok while we had it apart. Didn't have time to do the front, so went to drive home and do the front the following weekend. On the drive home wicked bad vibes starting at 45mph. Didn't drive it till the following weekend and regeared the front. Still wicked bad vibes.
2. Pulled the front drive shaft and vibes virtually gone. Took my stock DS to a driveline shop and had it retubed/balanced. Vibes slightly better, but still bad.
3. Down the rabbit hole I went. Ordered a brand new Adams DS. and installed that. Vibes slightly better yet, but still bad enough to vibrate the rear view mirror to the point that I can't see out of it from 60mph on up.
Removed my UCF Lopro trany mount, reinstalled my stock mount, and lowered the t-case skid down 0.75". Vibes a bunch better, but still not right. Now vibes are like a harmonic sign wave from 50 to 60 mph, then above 60 they get physical in the steering wheel and driver seat. At this point I could still remove the front DS and get rid of most of the vibes. Called Adams and complained enough that he sends me another new front ds. Maybe it was a bit better, but at this point my butt dyno is getting too sensitive to tell for sure.
4. At this point I figured I screwed something up with the front re-gear, so I take it to an offroad shop next county from me, as there is nobody in my county I can trust to do gears. The shop pulls the front cover and tells me that I only have 2 thousands of backlash and all the hard facing has worn of the gears. So, I have him install new gears. I come to pick up the jeep, drive it 30 miles to home, and vibes are the same. I park the jeep and notice oil puking out of both C's. Drive it 30 miles back to the offroad shop and say WTF? They take it back apart and found that they had install the wrong inner seals, so they fix that fuck up. I tell them I still have vibes, so they put the jeep on stands, run it, and proceed to tell me I have too much play in the stock rear drive shaft. At this point I think they were just trying to get rid of me, so I left.
5. So, I moved on to the rear. Ordered adjustable control arms, a SYE, and DC rear drive shaft. I have a local transmission shop I trust install it, along with a new chain and a bearing/seal refresh. I re-install the t-case
dial in my pinion, and nope, still vibes. Maybe better but meh. At this point I do a series of pinion angle changes to try and dial out the vibes to no avail. I call Adams and he sends me a second rear ds. Nope.
6. Pretty much fed up and broke, I just drive it and live with the vibes, trying to avoid the freeway when possible. As a last ditch effort I get a Barnes t-case skid in hopes that going with a thicker skid I could somehow change the harmonics, which it did, and actually helps some. So now we have a vibe that is annoying above 55mph but somewhat livable. Still not ideal, cause any vibe is not good.
7. For some reason or other the vibes seemed to have shifted from the front to the rear. I pulled the rear ds and now no vibes in FWD. WTF! On goes Adams shaft #3. Still got vibes.
8.This leads me to my current situation in hopes that basically replacing all the internals of the rear axle might find the culprit. Nope. Think that bring us to now. Sorry for the long read.
just asking since you said you have rotational play and hear a clunking every time you shift which is an exact description of a the Detroit locker lol
