[WSSix]

I FIXED IT!!!!!!! It was so simple too. I can't believe I missed it multiple times. Oh well, such is life. The one u-joint strap was not holding the cap fully. As I mentioned earlier, I replaced the rear u-joint due to it having a little bit more play than I thought was correct. Turns out that play was the cap moving and I just didn't see it. I noticed it this time though. I took both straps out cleaned them and filed the flats down so that I was certain no burrs or slight deformation would keep it from bolting down fully. I put everything back and the play was greatly minimized because the cap was no longer moving. Took the car out and there's nothing but smoothness.

I'm still planning on a new driveshaft as I need about a 3/4 inch longer shaft. I'll do it when I do the transmission and engine later this year.

This was such a battle and pain in my ass that it really had me questioning if I should be doing anything related to cars aside from drive them. Now I can finally move on to all the other things I need to address on this car.

Thank you all for the replies and suggestions.

Scott, to answer your questions. Yes, new sleeve. I'm going from memory but I want to say 25-26 in lbs to rotate pinion. I do remember it was 3-4 in lbs over. Only pinion was in place. No carrier. I didn't back it off any. Pinion rotates smoothly by hand.

I posted the 3 in lb question over on NastyZ28 as well. There's a gentleman that posts regularly, Big Gear Head, that sets up lots of rearends. He really knows his stuff. His replies helped me rule out that being the issue. Still not sure why it's making the noises though. It could be the TruTrac or simply the gears running through the oil. It was very interesting to listen the gears and carrier rotate without the axles in place. The gears churning up the oil is rather loud inside there.