Ok, I got a replacement used pan carrier, bolts, and a driveshaft with 90k miles on it. The driveshaft was marked '01, which is good, since my car is a 2001. I bolted the front in just snug, pushed the center pan down a bit to bend the driveshaft a bit to get it lined up with the coupler at the rear connection, attached the center bearing support the bolts to finger tight, and then went to start the rear bolts. I got them all started, but (here is my question!) the coupling had a space between the driveshaft joint and the rear diff/haldex, but small enough that I got all the bolts started with the bow-tie washers in place. I mean it went into the cup on the rear drive unit, but not so far that it touched the mating surface. I then snugged them down and the space closed up. I was not able to pull on the joint to close up the gap, I had to use the tightening of the bolts to get the space closed up. I tightened everything else, and took it for a drive. Is this normal that the driveshaft seemed a 1/4 to 1/2 inch short? everything else up to the front connection was loose so the part should have gotten into the right position after snugging the rear bolts. I think I did it right, any opinions?
Now that it is 4 wheel drive again and since it is a new car to me, this test drive was the first time I have driven it since driving home from previous owner as a front wheel drive car. When I let off the gas at any speed there is a low subtle whine. It sounds like it is coming from the back. (My next question) What most often fails on the rear driveline in these cars? I looked at the rear diff, and there was some oily crud around the drivers side halfshaft output, I did top up the rear diff with good low friction 75W-90 GL-5 gear oil, and it did take about 300ml before the oil started running out. Rebuild? Replace? New bearings and seals? I imagine it has to come out for any of that. Drive it and don't ever slow down with engine braking? Drive it until it gets real loud then replace? many questions.... But I will be happy if I can get help with the first 2.
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