New Alignment Bar Dimensions for GKN Driveshaft Assemblies?

[harringtondav]

Five year old VP SX-D coupled to a G5 VP 4.3 with 23400765 engine coupler.
I just did my first drive pull for inspection and prepping for driveshaft bellows replacement. I tried checking the alignment with my Merc bar, 1.010" spline pilot diameter. The bar wouldn't enter the splines. Hard stop at the coupler. I did some research. The Merc coupler and U joint splines are ANSI B92.1. Likely made by Rockwell like previous VP shafts. I checked DIN 5482-5480 std because the GKN assembly. Very similar 17 tooth 30 deg PA splines, but the coupler minor diameter is .001-.006" smaller than the 1.010" bar pilot diameter.
I also have a second alignment bar with a 1.0045" pilot. (long story). The bar wanted to start but didn't get past the coupler's lead in champfer.
I can take the old bar to a machine shop and have them trial and error dust the pilot down until it slip fits.
Does anyone have any knowledge/experience on this? Knowing the correct tool size would save me some time and money.
Thanks, Dave

Any insight on this?

 

[alldodge]

My understanding is all use same alignment bar, or at least I've always used the same and they work. The 1.010 is what I have

 

[harringtondav]

That was my understanding too AD. But my 1.010 bar wouldn't fit. Years ago I used it the check an OMC Cobra I was working on and it worked fine, just like it did for 25 yrs on Merc Alpha 2's.

 

[alldodge]

I would think if it doesn't fit then things have moved. Look closer at the mounts. Get the bar to go in straight, remove put grease on outer edge and slide back in, remove and check marks