Thanks for your replies. I checked out the TSB and my build date is Nov '03, and the symtoms are different. If I shift below 1900 the clutch feels normal. If I depress the clutch pedal above this speed, then the symtom appears. I have also experienced the stiff throw-out bearing in your first post, but not on this truck. I have purchased a complete Banks kit as well, but have only installed the exhaust system to date. The problem was present at 4 miles on the odometer. I now have 1700 miles on the truck. This would be a good opportunity to install a heavy duty clutch, but I have been unable to locate a 13" heavy duty aftermarket replacement. The only ones I have located are the 12 1/4" units.
I will keep you informed after disassembly.

 

Still no driveshafts. Dealer says the shop is having to send them to another shop because this is a new DS and the couplers are different and they don't have `em. Maybe tomorrow.... I really can't gripe about the loaner but I'm only getting 14.3mpg!!!!! I am getting 17.5 in my CTD. I'm drivin 80 miles/day..... Gas is $0.35 less than diesel so I guess it balances out...

Tryin to keep you all in the loop. I know many of you are suffering too....

 

Just so ya know that isn't a Dana 60, and their are no locking hubs made for it.

 

It ain't that AA 9.25" is it... I gotta check.

 

Yes it is, they stopped using Dana axles in 2002. Should be more up on what you are buying

 

Rear drive shaft is back from being balanced - it was out of balance. Front drive shaft can't be balanced so DC is sending the dealer a new one. Hopefully I'll hav her back Mon or Tues.

 

Just got her back after 11 days in the dealer.

Rear shaft was balanced - DC said new ones would have the same prob so replacement was futile (always wanted to use futile in a sentence).

Front shaft could not be balanced so it was replaced with a new one. Waiting on it to arrive is what took forever...

Going out for a test drive - fingers are crossed!!!

 

Vibration is still there.... Guess its the Al drive shaft that'll fix it...

 

Just wondering something. My dad has a 2004 (late) 1ton Dually. slight vipration at take off. then nothing till 50-55 ( oh its not a slight vibration) stops then after 65 it starts off again. has had the drive shaft replaced, didnt fix the problem. Dealer Service manager said it was a defect in the truck and the dodge knows about the problem but wont do anything about it.

 

Just another data point....

With the stock Michelins my truck has been smooth at all speeds. I put on a set of Cooper M+S tires and noticed some vibration at speed, which I would have assumed was driveline vibration if I didn't know any better, but I do know better as there wasn't any with the other tires. PSI is about the same in both tires, actually a bit higher in the Michelins. On newer stretches of asphalt road there isn't any vibration with the new tires, so it's probably not out of balance or out of round tires. It seems that the road condition is being transferred more strongly to the cab with the new tires.

I'd at least make sure that the tires are nicely balanced before swapping driveshafts and all. I've noticed that some shops do a lot better job than others, where I've had better luck at America's Tire or Costco around here. I guess it's the operator as well as the balancing machine.

 

Steve-1, I had the same problem with my truck. The 03s have a TSB for a weighted hydro boost line. The weighted line is supposed to come on the 04s but the early build trucks don't have them. None of the dealers around here would install the weighted line on mine so I made my own weight and it solved 90% of the problem. Some people have tie strapped the two lines together and had some success (mentioned in an earlier post). I took about one pound of lead weights and tie strap (zip tie) the weights to the line. I have slid the weight up and down the line and found the best success near the center, between the pump and brake boost. The new line is $60 from the dealer. Before I put the weight on the line I had vibrations all over the place (drivers window, gauges, A pillar gauges, etc...).