CK5
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What the heck...................

The shaft slids easily but I do think at full droop the ujoint at the t-case is binding, ..

Bet you never tried sliding the shaft in and out under a load. Put a couple thousand ft-lbs. of torque into the shaft and see how easy it slides then.

Not saying its your problem but at least something to consider.
 
Man, all you folks worried about drive-line angles. There was a swamp buggy that I saw once, more years ago than I care to think about, that had that problem solved.

The front and rear diffs were turned so they faced straight up. There was a shaft that came out of the diff and went up to some kind of a gearbox on the frame.
We're talking about 4 or 5 feet.
Then there was another shaft that came straight out of the transfer case and drove that right angle gearbox.
Talk about easy drive-line angles, I think that one used LoveJoy couplings instead of U-joints since it was a straight shot.

The shafts that went from the right angle gearbox to the diffs had a LOT of slip joint range, but the U-joints did not see much angle.

.

So if you take standard style axles (D60, D44, 14-bolt, etc...) and point the pinion straight up you wil be starving the pinion bearings of any gear oil. The only way to make this work is to do some sort of custom fabrication to accomodate this, like a pump or maybe packing the bearing with grease?? In any case, it wouldn't last very long without doing something.
 
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