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Cannondale, yes i keep the front cross shaft bolted in place with suspension in and track loose.
You're right about the housing lugs being machined, it's the tunnel itself that's not square verticaly to the driveshaft. The easiest way to see if you need a spacer behind the top lug is to loosen...
For you guys using the shaft saver, torque it down with the top calliper bolt removed to square the bearing on shaft. You will notice a space between the top bolt hole of the calliper/bearing housing and the tunnel. Fill the space with an aluminum spacer to keep the housings square to the shaft...
Did you check your head for cracks, a few of them had a small crack at the coolant plug on top of the head between the cams. Like plug was over tighten from factory. There’s a post on arctic-chat.
I'll keep a close eye on it. Hope its that simple..
Dan, oil level is ok and no coolant mixed with oil. Running TD SM Jukebox.(MS16 most of the time). The sled works great, never did overheat.