About a month ago I went wheeling and broke the yoke on my front axle. Attributing it to nothing more than I put too much of a strain on it I ordered a new one, along with a Tom Woods driveshaft. I went out over the weekend and I hear the same noise I did just before I broke the last one. So I stopped and took a better look at what was going on. Turns out when my drivers side tire is fully stuffed and the passenger is at full droop my driveshaft is contacting where the upper arm mounts to the lower on the drivers side radius arm. Noe I've got a few things that I believe to be part of the issue. My drivers side upper control arm bushing on the axle is shot. I still have bump stop and limit strap tuning to do. I've got 13" of functional travel. Looking for anybody who's had this happen. I'm thinking more bump stop work and some limit straps to jeep things in order should do it, but some outside perspective is always nice.

 

What brand of arms and how much lift do you have?

 

Rough Country arms, between 5"-6" of lift. I haven't measured in a while, but I know all the armor has brought it down from the 6.5" I started at.

 

Sounds like your track bar is off and the axle isn't centered.

 

Does one of the uppers have a bend in the fork of the mount? Thats how my Clayton radius arms are to prevent any contact with the driveshaft or housing.