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Haven't read the TM but a preload would be like installing one end and tightening it down in say it's top position and then forcing it down to hook to the axle, where the rubber spring would be putting continuous torque, trying to return it to a neutral position. It makes sense, but I wonder...

Yea, I couldn't agree more. Mine is a 929A2 that can haul a good size load for that frame size truck, and articulating with a load could cause this trouble fast enough. My real nemesis seems to be having to reverse in low transfer case gear. 74M35A2 mentioned having a couple straps, which...

I'm not being critical, don't take my various questions and statements the wrong way. I hope yours hold up and you never have to test to failure. I've considered using them in a four link on a 4x4 but would have an entirely different mechanism to keep it centered...a "Watts link".

In line with the axis of the bone so that extreme twist has room to go 30+ degree.....but like you say, you may never articulate that far. Don't saturate the weld heat too deep. I was thinking your flat with 2 screws would be nice, but not near as fast as welding.

I don't have any that are giving up that I know of so thankfully don't have to make that decision (knock on wood).

Here is the problem. When we articulate and go to extreme, the housing (of the bone) twists sideways. The rubber is supposed to take that compression (one one side of the shaft) and tension (on the other side) and return to it's straight position. As the rubber gets old, it doesn't take much...

I'd use fine thread and take one of my old taps and flatten it, taking about 1/4" off so it will tap to near the bottom after running a (fine, new) tap down. Caution, bottoming the tap gets solid fast and you can break them off easy.

I bet the racket and damage left you with stained....well newfound pucker power.

Given the limited range of flexibility required, I wondered about a wrap or strap that would go around it in a figure 8 pattern and hold them on. Even something like strips of innertube that could be stretched tight to keep it from moving sideways and off.

Has anyone made one from UHMW plastic and (something like) bolt/stud w/washer?