Got the DS for the 96 sport to use the flange for my t case.
Found in the pile o driveshafts a perfect length front driveshaft for a Heep Grand Cherokee. The U joints are the same and it has a stock double cardan, but it uses a different style to connect to the t case
I am going to transplant the flanged double cardan from the Explorer driveshaft to the heep driveshaft. No need to get it shortened and it should work. I got both shafts for $81, so I should have a perfect front d shaft for not much cash. And as a bonus the heep front d shaft diff yoke is the same as my D35, so I don't need a conversion u joint.
From the top down:
Stock AWD D shaft
F150 D shaft cut down a little bit
Jeep front d shaft
Explorer Rear d shaft
End shots same order just sideways - notice the jeep shaft has a different connection for the T case
Yoke Comparisons: Left to right
Jeep
Stock D Shaft
F150 shaft with conversion joint
Ford D shaft some what taken apart
Ford flanged piece
Jeep double cardan
U joints- AZ only had these three. The brute force went in the middle u joint because it is impossible to get a grease gun in there anyway. The other two have zurks.
Completed Double cardan
Completed D shaft
Comparison shot- the DC driveshaft is about 1/4" longer than my cut down F150 shaft. It just barely fits between the diff and T Case, but it is not bottomed out.
Last picture- bolted up rear angle
I am running 3 of the stock size u joints for my truck on a Jeep Grand Cherokee front D shaft with the double cardan from a Ford explorer sport.
No cutting or welding. Just a bunch of damn rusty u joints and 3 new ones. I took pictures but wont be able to upload them until tonight.
I took it on a road trip and no noise at all. At certain speeds a very small vibration in the floor, I suspect that is from the weights I left on the driveshaft. Now that everything is different, I don't need them.
The only people that need this are those with the 4406 AND a suspension lift. If you dont have any suspension lift a stock F150 driveshaft with a conversion u joint will work.