Hey everyone, I have a 4cyl 95 wrangler, my driveshaft decided to do a combat roll off my transfer at about 70, i found that i wore my u joints out (rookie mistake, should have noticed the vibration) so now I have the new extension housing with a new bushing and my shaft does not slide through, is this normal?
I'm trying to picture what you're describing. So you are saying your u-joints broke and your DS slipped out the TC. Did it ruin your TC output tail cone (new extension)?
did you add a new tail cone or do a SYE? If you added a new tail cone and you're trying to slip the old slip yoke in, I would inspect it close. It went flying around at 70 mph, I'd also have your DS checked out as it must have hit a lot of things spinning free at that speed.
Okay, now I see your photos. So you put a new cone on, I'm assuming it fits flush with the TC housing, you put on new snap rings on the shaft and the end of the cone had the rear seal bushing in already, you added the lock ring and cover. You say the driveshaft stops at the bushing, which is good you don't want it pushing against the bushing, this is your slip yoke. So I'm not sure where the problem is, does the slip yoke not move along the shaft?
Did you put a little T fluid on the yoke and around the seal? It needs to be tight to keep from leaking. I'd put the cone on the TC so once you get it in and on the shaft you don't have to pull it off.
The fact that it went in means something is stopping it from going furthur. It could just mean the dry shaft and dry seal are sticking so try ATF. The other problem could be what I mentioned earlier. Did the slip yoke get damaged when it flew off at 70 mph? Are there burs on the yoke? Run you hand down the shaft with some ATF and see if it's smooth.