I have a 4" lift on my 2010 Unlimited Sahara with automatic (still D30 front axle). I have not yet changed the front driveshaft although it is on my list.

My problem so far is finding a replacement drive shaft that will handle the 7 degree angle between the pinion and drive shaft. Every double cardan driveshaft I read about so far says I need to reduce the driveshaft-pinion angle to zero. This is not possible without ruining the caster.

I don't want a driveshaft that's going to tear itself apart or worse tear the transfer case apart due to vibration.

Anyone know of a front driveshaft that will be happy with a 7 degree angle?

Thanks!

 

You are wise to be concerned about this. Too much pinion/drive shaft angle is the main ingredient in the recipe for disaster with a double cardan at the front of the t-case.

Reducing the angle to zero is the best it can be, but I believe people have been OK with 2 or 3 degrees, and they could live with the resultant caster.
It's a compromise for sure. All you can do is cautiously try it.

Another option is to have a single joint on each end, and adjust the pinion angle to match the angle at the t-case end.
(I don't recall having read about anyone trying this combination, though.)