Chris,
It's never happened to me, but some time ago I heard of a problem similar to
yours--the guy replaced everything. Turned out, after much head scratching,
that the grease caps on the U-joint were either just a bit too short or the
whole assemble was just a little too small--we're talking thousanths here.
What was happening was the whole yoke was able to slide back and forth in the
flange. The clips had to be removed and a shim was made from an aluminum can
to take up the slack.
Visually re-check the U-joints, looking for excess room between the grease
cap and the retaining clip, or the yoke within opposing grease caps. Can't
assure the cure, but it may be worth checking.
Charlie B.
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