10psitx wrote:op, you really have a lot to learn, as one poster said there are many late model domestic vehicles that have oem aluminium drive shafts. The issue you will run into is mating the OEM 240sx transmission and diff yoke to the Aluminium drive shaft, there is a size difference between the two. A U-joint that will fit the aluminium drive shaft will be twice the size of the 240 yoke thus rendering it non compatible from that point of view. I may me wrong.... but i'm yet to see a U- joint with two different sizes for the caps. Usually when you "custom build" a drive shaft for swapped cars you generally use the same material...eg- all steel or all aluminium so both the yoke and the drive shaft tube can be "welded" together.
what you failed to account for is the 1 peice aluminium drive shaft that is sold for the 240 uses the same size U-joint as stock, they are made by Spicer, so they fit the steel yoke and allow it to connect to the aluminium tube.
What your machine shop will need to do is get a damaged aluminium 1 peice 240 drive shaft cut off the part that recieves the U-joint, fabricate a taper to account for the size difference and weld it to the "ranger" driveshaft, then get a spicer brand u-joint and install it between the steel 240 yoke/s and the modified aluminium drive shaft.
Just so you know ....i used a 2003 chevy suburban 1 peice aluminum Drive shaft and a damaged 240 aluminium 1 peice drive shaft to build mine...its was quite expensive and alot bigger that the stock one, but it can be done....just not worth the effort or cost.
There's such things as different size ujoint are you serious go on npd.com they sell ujoints on there that mate a 1970 mustang drveshaft to a 1993 t5 yoke which is not the same size there are plenty of conversion ujoints available

