Have you looked at the coupler splines real good? Shine a flashlite thru the gimble. You can also feel them by laying on the motors and reaching over and feeling the splines with your finger. The splines should not be sharp. Sharp and pointed splines mean they are deformed and actually make the ID smaller, so an alignment tool will not go in the coupler. You need to know that the couplers are good to start with. With worn hinge pins, drives that need to be beat on to install, look real close at those couplers. Also, what did the grease look like that was on the input shafts when you 1st removed the drives? fresh grease, no grease, or dried hard grease?

How far is all the way in on the alignment tool?,,just wondering in case mine is diff than others.In inches??? My grease wasn't too good but not completely dry. I'm not home now but the splines on the coupler made flat marks on the tool . I'll feel further in to see about inside the coupler. I'm still concerned that the rear align seems the culprit,I know this shouldn't be because it's all Fac. none adj back there. Maybe I'm off side to side in the front? I'll check.
What is a good mail order source for those sythane washers and hinge pin sleeves on the bellhousing,also need a water pick-up hose retainer(the plastic insert on the outdrive side of the bellhousing)? Does BAM sell these little parts?One member said he'd help so I'll try again with him to.Who do you guys use?My local dealer has nothing and I don't like him !!

www.mercstuff.com they will have what you need, call em they are real nice people.

thanks