The steel hard dash and aluminum soft dash shafts are 90º off from each either as well. I've used the aluminum shaft in a hard dash truck and had to pull the wheel and reclock it, didn't find any length issue with it however. Never tried it the other way however....
There's a centering peg on the rear diff flange, but there's a ball or bushing inside the Rotoflex that rides on that peg. It doesn't spin on it of course, but there is some movement as the Rotoflex...flexes. It's a bit like the centering ball in the double-cardan joint.
Tom Woods makes some...
Any good driveline guys in your area? Might be worth having them check the balance. And what about the centering ball in the Rotoflex? Even if the Rotoflex itself is okay, that ball might be shot and allowing it to go off center just a hair. Not that I've seen it happen, just sort of thinking...
I don't think any worse than an LT230. You might want to get rid of the Rotoflex though and go to a straight u-jointed shaft. Those things don't like to operate at an angle and a 2" lift could be just enough to flex them a bit too much. I'm going to swap out the Rotoflex on this '95 for a...
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