D27 D25 U joint help

Some time ago I received a D25 ankle as part of another deal. I found out later it had a powerlok universal.

I decided to replace my D27 with this D25, keeping the D27 axles. As I tried to connect the drive shaft I found the D25 u joint flange was larger that the one on the drive shaft.

I had a spare drive shaft with the large universal joints, but now the flange on the transfercase output was too small.

The Small u joints are about 2 1/2 inches wide the larger u joints are about 3 1/4 inches wide.

My next thought was to make use the small end of one drive shaft with the large end of the other drive shaft. The inner slide joints are different sizes.

Today I finally got the flanges off the axles to swap. The larger flange off the D25 has a 10 spline connection.. The flange off the D27 had a much larger spline count.

Is it possible to get a small u joint flange with the course splines?
Is it possible to get a large u joint flange to attach to the transfercase?

is it possible to get a universal joint which would be wider in one plane and smaller in the other plane?

If possible I would like to keep the smaller drive shaft.

Thank you for your help.

 

You can use another transfer case yoke with the small joint and coarse spline. The dust shield may not work but the yoke will work on a 25. Should be fairly easy to find one as most people go the other way, to the larger stronger joint and drive shaft. Put an ad in the classifieds.

 

Thank you.

 

i put a larger ujoint flange on one end of my driveline and it has worked great for two years now.