my brother has a 93 cherokee and everytime it gets in a bind both yokes at the rearend breaks. besides bigger axels is there anyway to fix this?

 

don't drive in 4wd on the street......

 

agreed!!

 

Is it lifted? Sounds like some angles are off.

 

OK crazy question here, did anyone ever take the DS apart and put the yolks on crooked instead of lining them up...Tj

 

Another dumb question. Do both axles have the same gears in them?

 

yea its lifted and if you dont know your not supposed to drive in 4 wheel on the road you need to be slapped haha it has 3 1/2 inch its broke a few times even had a bigger driveshaft built for it. somethins gotta be off somewhere

 

is it stuck in 4wd? Its happened before.....

are his pinion angles correct...and are gears matching front to rear?

 

dont know about the pinion angle but its factory axels chrysler 8.25 and i think dana 30 in front and no its not stuck in 4 wheel drive but the rearend is locked but it has broke once or twice before he locked it and broke after

 

are you sure that its not locked in 4wd? even if the shifter is in the 2wd postion the transfer case could still be stuck in 4wd.

did he properly set-up the new yoke after he broke the first one? if the pinion preload and whatnot weren't set-up right then that could be his problem.

 

it only breaks when in a bind like climbing a rock wall or pulling someone if it jerks. where we go ridin at other people have been having this problem but noone knows how to fix it. everything was put in right. if the transfer case was still locked in it wouldnt drive to good on the road.

 

sounds like a good mud hole...

 

what size tires are you running?

I still am leaning towards the yoke not having been installed correctly or something wrong with the axle.

I have a 99 Chrysler 8.25 stock with 3.55 gears and I BEAT on it. Like, I powershift(yes, i know its stupid, but its STUPID FUN!!!!) and put my foot to the floor multiple times a day. I have a 5spd which makes things all that much harder on the driveline and I've never had any problems like the ones you speak of.

Any way you look at it, it boils down to this:
Something isn't right with that rear axle if you keep having the same problem over and over and over. Its one of two things: A: something wasn't installed correctly B: Something is broken and breaking the yoke over and over again is just a symptom of that.

With it only being a 27 spline 8.25 I'd say you should swap in a different one, preferably a 29 spline of 1997 or newer vintage. They're only marginally weaker than an XJ Dana44, can be found for as little as $35(what I paid for mine) and are very common as rear axles go.

 

Sounds like the pinion angle is off and he's getting axle wrap and the two yokes are coming in contact with each other.

 

thats very possible also. he'd have to have some REALLY bad pinion angles for that to happen though