well today i encounter a fierce opponent with my rig and sadly lost, drove into a deep steep sided ditch haha ended up getting stuck in the jeep without 4x4, my front axle shaft u joints completely broke off inner and outter so had to call a couple different buddys to see who was available, and the ram squad showed up (96' single cab 4x4 5.9, and 06' 4 door hemi 4x4) my buddys single cab got me out and i was able to limp home..

now i searched for an alternative to my issue without having to dish out money for new stronger axle shafts, or upgrading axle completely, when my buddy told me about metal strengthening, i was curious and looked it up, found that its not to hard to strengthen by 'double'!!!!!! i plan on making a trip to the jy to get axle shafts for both sides and try to make them 'stronger', if anyone has done this, or has heard of someone doing this give me some feedback and or info, the procedure doesnt seem hard, just time consuming, will be posting pics tomorrow!!!

 

Not fab. Moved to chat.

 

Does your rig have ABS? If not, pull some ABS shafts from a 93 or newer Dana 30 (92 and older have the vacuum disconnect BS) and put some new spicer joints in. The ABS model shafts take a stronger 297x U joint than the non ABS with 260x joints.

 

Get shafts and throw in 760x u joints and grind the shafts to accept full circle clips.

Metal strengthening these shafts is BS.

 

So that is a spicer part #760? Is it easily available in parts stores?

 

Let's step back a moment. OP didn't mention the year of his XJ. Don't the newer models have stronger axles/u-joints from the factory?

I need to google this topic..

 

Probably, I don't know off the top of my head. Normally cheaper to order an have delivered a few days later.

95+ came with the 297 u joints
Before that was the smaller joint (number just slipped my mind), unless it had ABS brakes. Then it got the bigger joint.

 

Is this for driveshafts or axle shafts?

 

I'll take a big joint, if you got one.

 

Spicer replaced the 297 with the 760 in the early 2000s. Exactly same joint but they are supposedly better metal so they are stronger

 

everything you need to know about upgrading to 760's
https://www.cherokeeforum.com/f46/blue-prius-131319/index12/#post2058717

 

Polishing and shot peening the ears should help to prevent deformation,elongation, stress fractures, etc. Problem is most shops don't do this any more.

 

I would of course recommend the 760 joints, and get yourself some quality ujoints like good ol Spicers. There's a reason most aftermarket chromo shaft assemblies come w/ 'em standard...

I've personally witnessed 2 broken shafts due to the fact they spit out a ujoint cap, so either tack welding the cap or throwing on one of those "almost alloy kits" (think I paid $30) will do the job. Think I got 'em from iron Rock. You can't beat 'em for $30... worth my time in money and they fit awesome. That's currently my spare setup should I lose a chromo...

So... Spicer joints, weld the caps and use and abuse... if that doesn't cut it, then you better step up the shafts to chromos or find a find a bigger axle...

 

So, removing metal from the shaft to make room for new clips makes them stronger? Got'cha...

 

dont be stupid. it's to make the ujoint stronger. or really, just make it impossible to have a cap go flying off and take the whole shaft with it. 95-01 d30 shafts are plenty strong enough even on 35" tires. shaving a bit off the inner ear is no big deal just dont go overboard