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Re: driveline vibration
1) make sure that your driveshaft is rigged to be -2 degrees (pinion nose down. shim as required.
2) with a dial indicator, measure the axial runnout of both the transfer case flange and the axle flange. should not be more tha 0.004". if higher, you might want to have the flanges machined.
3) with a dial indicator, find the high spot on the flanges. Does it match the yellow paint stripe? If not, remark it.
hopefully this will help you figure out what is going on
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