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Discussion Starter #1
So i installed the 6 inch Zone lift kit today on my 03' 2500HD.. i get everything done and go to connect my front driveshaft and its about 2 inches too short??? what gives? this kit is not suppose to require any drive shaft mods. i'll be contacting ZONE tomorrow to see if any one else has had this problem. looks like im going to have to take it off and go get it lengthened. not too happy about this :confused:
 

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That's very weird. You sure you got it on right. Not trying to be a smart as. Try pulling on it pretty hard to come forward. May take a few really good jerks to pop free
 

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Discussion Starter #5
Ive pulled it out as far as it could go..the instructions show it just bolting right up not even needing to pull any of it out. im just gonna get it lengthened 2 inches. its only $30.
 

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I had a similar problem and was not happy when I held it up found an inch gap. It took a little pulling and I got it to slide out far enough to connect it. Only thing is now the dust boot is not covering the connection and a small length of the splines are showing.
 

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Ive pulled it out as far as it could go..the instructions show it just bolting right up not even needing to pull any of it out. im just gonna get it lengthened 2 inches. its only $30.

I would be VERY VERY leary of someone who is going to re tube a driveshaft for $30.......Just saying.
 

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I had a similar problem and was not happy when I held it up found an inch gap. It took a little pulling and I got it to slide out far enough to connect it. Only thing is now the dust boot is not covering the connection and a small length of the splines are showing.
i know a guy who works at the shop. he's done all my jeep driveshafts.
You guys also need to make sure you get the splines covered with that boot, maybe slide the back onto the transfer case and clamp the boot further down on the yoke shaft. Without that boot, those splines will get rusty and that yoke shaft will be stuck HARD in that t-case.
 

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I would be VERY VERY leary of someone who is going to re tube a driveshaft for $30.......Just saying.
Meh, It doesn't take that long to do really.... Ive made a bunch of driveshafts, lengthen, customize them for fellow mud bogger dudes around Ft Mac and what not.... All I asked for was a case of beer....
 

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Discussion Starter #12
if i wanted it to fit then id have to take off the boot and have splines showing..i dont really want that so when i have a day off i'll just take it to get it lengthened...why would mine not be long enough but others long enough? doesnt make any sense..
 

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Meh, It doesn't take that long to do really.... Ive made a bunch of driveshafts, lengthen, customize them for fellow mud bogger dudes around Ft Mac and what not.... All I asked for was a case of beer....
OK, thats all fine and well that your ham and egging stuff for your buddies. But i work in a driveline/machine shop with inventory, insurance, employees, a $30k piece of equipment for balancing the stuff that requires balancing, and other various overhead costs associated with running an actual business. Ive had the pleasure of straightening out plenty of "home" built driveshafts as well of plenty of stuff that has been put together by good machinists that are not in touch with the fundamentals of building driveshafts.
 

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just put mine in and he boot popped off too and the boot is too short, drive shaft bolts up but boot wont hold, anyone have a fix or call zone.....i really dont want to make a drive shaft
 

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Discussion Starter #15
I just got a longer boot for mine and used a hose clamp on each end to tighten it down. Worked perfect. I had an old stock rear driveshaft boot from my jeep wrangler wrangler and it worked great.
 

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i'd call zone that's bs!! but if you decide to add to the shaft, push the shaft in some and measure so you have a little play room... i wouldn't measure with it pulled all the way out..

personally, if they sold u a kit that supposedly didn't require any driveshaft mods, and it obviously does, i'd think they should send you a free front shaft or pay to mod your's...
 

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if you search 2500hd zone lift, looks like a few other people had this problem, and maybe a lot of other people just dont know they have this problem....
 

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what year and model jeep was the boot from?? did it fit good, same diameter as the chevy one?? i didnt pull the shaft out to see how much the splines are still in tranfser case did u measure it to see if there is enought spline still in case thanks
 

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Discussion Starter #19 (Edited)
Came off of a 98 wrangler sport. The Fitment was perfect. Perfect length and diameter. Plenty of spline still in the t case. Been running it like that for awhile now with no problems. I was running 2wd for the longest time and didn't feel like spending $150 for someone to hack up my driveshaft and lengthen it so I just started looking around my shop and found that boot I had in a box of random stuff. Had been sitting there for 5 years and I gave it a shot and worked great. Cost me nothing. I'll post some pics for you tomorrow if you'd like.

Back when I did my lift...I think I was the second guy on here to have the zone, after nousef0raname...so I couldn't figure out why I had this.problem because no had any experience with zone. I contacted zone but they had no idea what was wrong. The only other time I heard of this problem happening was with a guy on here with a LMM
 
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