Just swapped out u-joints in my 2005 1500 with the 3.92 LSD rear. one of the driveshaft to pinion bolts was 90% seated when it started getting tight and probably galling/stripping. I kept going, hoping it would just seat. no luck, there is a .050 gap. The other three torqued up just fine. I am fine just cruising around the city, driving easy, on the three bolts, but eventually I will need to haul some heavy loads and tow a trailer. not comfortable with only three bolts for that.

The pinion has a second bolt pattern on it. I am assuming that the second pattern is not exactly the same as the one that bolts up the stock driveshaft. Anyone know what driveshaft adapter flange will mate to the other bolt pattern and fit the stock u-joint size of 1.063" cap diameter, 3.620" cap to cap width?

otherwise I am faced with trying to drill out and tap for a larger size bolt. I really should drill out the opposite tapped hole in the flange to keep the driveshaft balanced. Really not interested in doing that.

 

Why not replace the pinion flange? Seems those would be easy to come by.

 

Hmm. Not a bad idea. My concern would be getting the correct preload on the crush washer of the pinion. I might have to go that direction though. I am going to try to see if the dealer might own it. The truck was in last year for a recall of the pinion bolt missing loctite. I am sure that they are the culprit of why the threads stripped. Now, I just have to convince them of that...