I have a 2004 Discovery 2. Bought it used. Felt some vibration and started to hear "chirping", so parked it and I ordered a new drive shaft. Got the old shaft off and saw that joints were starting to come apart in the rear. Seriously caught it just in time. When I tried to install the new shaft, I can't get it to align properly. If I bolt in the front four studs and bolts, I am then a couple of millimeters out of alignment for the rear four studs. In looking at the old shaft that was about to go, there is some play in the rear joints due the damage at the joint and perhaps this let the rear fitting get slightly out of alignment?. There is a little play at either end, but not enough to allow me to properly align the studs.

What to do next?

I do have the locking differential feature and can lock the differentials and take it in to a shop. But what are my alternatives before brining it in?

 

Chock your rear wheels, engage the parking brake, put the transfer case in neutral, jack up the front of the vehicle and you should be able to turn it so you can align the bolt holes up properly.

 

But do it very slightly. Just enough to line the holes up and leave the front part of the driveshaft bolted up.

 

Thanks, I'll give it try in the morning.....got to get it done before football starts!

 

And leave the front bolts somewhat loose. Don't tighten then all the way up till you get the rear ones started and tighten them up. Make sure you alternate (cross cross) when tightening (like a 4 lug wheel). Sorry to keep replying but my mind isn't completely focused. Hope this helps

 

Don't need to put t-case in N, just raise a front tire so you can rorate it a little to Line up holes,

 

Just ensure you buy a new driveshaft with greasing zerks in every UJ either in the cruciform or on each UJ head. You've been especially lucky on this one so ensure you pump in plenty of grease. Under normal circumstances it could have cost you a transmission casing and a lot of hassle so send Santa a nice card eh

 

Yea he didn't need the transfer case in neutral but I figured it might be a bit easier to turn the output flange than the driveshaft with it attached to the wheels. But did you get it installed yet and how did it go?