Drive Shaft Vibration

Works for me! Unfortunately I messed up the pinion flange and have forced the wrong thread bolts In there. Might be ordering a new one. Any idea on how much a pain replacing that will be?
 
Works for me! Unfortunately I messed up the pinion flange and have forced the wrong thread bolts In there. Might be ordering a new one. Any idea on how much a pain replacing that will be?
That is going to suck a good bit if you have to replace the flange. I would see if you can tap the threads to clean them up if possible. The issue is the crush sleeve that is behind the pinion flange, it should be replaced along with the flange and this can affect install depth of the pinion and ultimately can affect the pattern of the gears. I would try to avoid changing the pinion flange if possible
 
I finally got the DSS mounting ring off the flange. I went through 6 cutting wheels. I tried to use vice grips to get the bolts out but the heads sheared off. I'm considering trying some type of easy out and a tap. I've also called Ford to get an estimate on replacing the flange. (probably won't be cheap since I believe they will pull the pumpkin out of the car).
 

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Not yet I was in a wedding on Sat. I'm pretty sore from the dance floor. I might try to get to get out there today but I doubt I'll be able to.
@84Ttop I've never used a tap set. Any advice?
 
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Not yet I was in a wedding on Sat. I'm pretty sore from the dance floor. I might try to get to get out there today but I doubt I'll be able to.
@84Ttop I've never used a tap set. Any advice?
Lubricate the tap with oil and ensure its straight. You may need to work it back and forth to straighten a really marred set of threads out
 
GREAT NEWS! The Mustang is fixed! Ramsey's was able to turn the car around in a couple of hours. They cut the bolts flush with the flange and were able to drill them out!. The best part is the new 4" driveshaft doesn't seem to have any vibration that I can feel as of yet.
 
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There is a small amount of harmonic vibration right around 60 if I'm in fifth gear if I drop into 6th it completely goes away. It's not bad at all. For me that tiny bit of vibration is worth the trade off of knowing it won't break.
 
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On my stock V6, they replaced the driveshaft and it helped. Mine visibly wobbled at the center bearing support. This helped by 50% but it's still there. I have just escalated this issue with Ford Service and hope we can get it to a liveable level if not gone. But I'm not optimistic.
 
The vibration has gotten worse as time went on. I have also been experiencing an issue with the bolts on the DSS Axles backing out. They sent replacement bolts but I haven't replaced them yet. I did swap back to stock axles though in hopes maybe my worsening vibration issue would get better. It didn't.... I emailed DSS they asked me to index the shaft 180. I did that and the mild vibration went to a severe vibration. It was like driving down an old brick road. They are offering to replace the driveshaft again. They are suspecting the CV may have gone bad. This would be my third driveshaft from them so I'm considering selling it. I can roll around on stock till I find another D/S. I've heard good things about Shaft Masters. Anyone else have any recommendations? I think DSS has had amazing customer service but I would like to be able to daily drive my car without any worry.