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Discussion Starter #1
Over the past couple of months, I began hearing a sort of hollow, metallic "tink" when I'd start off in first. Replace u-joints thinking that might be it. Nope. My mechanic pulled the aluminum shaft (2 years old) and put in an original shaft he had. No noise. Inspected the aluminum shaft more closely and found a hairline crack at the back end kind of hidden just above the weld. Glad I found it this way instead of 70 mph on the interstate. I have advised the vendor of same.
 

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Good luck with getting that replaced.
:)
 

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Discussion Starter #3
Replaced it with an original Ford unit my mechanic had. No more aluminum for me.
 

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Unless you really strained and cracked that Aluminum drive shaft, the crack might be "stress corrosion cracking". High strength Aluminum alloys (7XXX, 2XXX, 5XXX) are susceptible to stress corrosion, particularly when welded. Why don’t you get the manufacturer to investigate it and replace it? Aluminum shafts are great if designed properly. Find out what alloy the tube is.
 
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