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Is it possible that the frame was warped enough that the rear end is too close to the tranny now, which makes the drive shaft too long? If the shaft is too long, bumps in the road could be causing it to bottom out on the slip joint, which would transfer a lot of energy to the tranny. If that is the case, you should be hearing a fairly audible bang when you hit bumps.
2002 F250 CCSB 4x4
PHP Phoenix, John Woods VB, NUC bypass, 6637
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