DISCLAIMER: I am not responsible for the 'before' condition of this shaft. I just bought the truck. And because I don't have an extra $300 burning a hole in my pocket, I decided to take matters into my own hands. TIG clinic is now in session:

 

Wow that actually looks better than I expected

 

Why, thank you. I wish I could say I actually laid down the welds, but I had a buddy from work do it. I tig a little bit, but he puts me to shame.

 

Rebalance by a shaft shop?

 

Not yet, but it's on the list.

 

Good work, but who told you a replacement roto-flex would cost $300?

 

Instead of buying a $100 used shaft, you used a $3000 TIG welder to fix it?

Makes sense to me :flipoff2:

Talk about polishing a turd. In the end, you still have a rotoflex driveshaft.

 

My mating flange on the rear differential broke as well. I first bought a replacement 3 bolt flange (used), then found a deal on a used driveshaft from a 98 DI that does away with the rotoflex. So I got a used 4 bolt flange and my changeover went well.

It was a bit of a chore removing the old flange from the rear diff, but I am happy to have gotten away from the rotoflex setup. It does very well with the used driveshaft.

 

It was a free fix. I work in a fab shop, and it took 15 mins. I replaced the flex coupler, obviously. I thought the only other option was a shaft with a u-joint at the rear, which I've only seen in the $300 range... am I missing something??

 

Land Rover made a change somewhere along the way that did away with the rotoflex and changed over to the rear u-joints as well. It uses a four bolt flange rather than a three bolt flange. It is true that new "upgraded" driveshafts are available like you said, but you can also go used if you find one from a 98DI or possibly mid 97, I do not know the exact change over. LR was known to make changes whenever they chose to and tracked them by VIN #.

My used 98 d/s and required parts was roughly $100. D/s was sourced locally for like $50 or so, then flange and new seal accounted for the rest.

Paul and PT both provide great prices on used parts, so as a newbie, it is good to check with them when needing parts which is almost constant for a while.