4406 T case Front Driveshaft Question

[eblightning]

Just installed 4406 t-case, I have a front shaft from a 1999 F150 4.6L. The shaft is too long by approximately 1/4" fully compressed. My truck is equipped with a superlift 4" suspension lift. I'm quite baffled as to how the shaft is too long. Several other forum members have completed the swap without encountering this issue. The only way I can get the shaft in place was by loosing the t-case from the extension housing and loosening the front differential rear support bracket. Even then the preload would have been way too tight and would have damaged the t-case and front pinion bearing. Has anyone ever encountered this? I am going to measure the shaft again tonight when I get home from work but all references describe the length as 40 1/4". Considering the slip yoke travel, it appears that I need the shorten the shaft by at least an inch. (sigh)

 

[2TimingTom]

Measure from flange to flange at normal ride height. Take that measurement and your driveshaft to a driveshaft shop. Should be a quick, easy and cheap fix.

 

[boominXplorer]

You can cut some of the open side of the slip yoke off for it to fit. You will notice it will vibrate over 45 mph though since the superlift changes the front pinion angle. A double cardon joint is needed. You can make one from a 1st gen or jeep front shaft.