I,ve got a '95 SLT ClubCab 4x4 with a 3.9auto. Whenever I use 4wd [high or low] the right front halfshaft snaps at the inner CV joint. I measured both sides from the stubshaft flange to the back of the hub, the right side was 3/4" larger distance. Next I made a spacer out of 5/8" plate to mount between the stub and halfshaft to shorten the distance. I still break the shaft in 4wd. My front axle housing has equal length stubshafts and axle tubes. I do not have a vacuum shifter on the right tube, other Dakota's I have seen have a different front axle assembly. The diff. is open but very stiff, I've had it apart and cleaned/inspected all parts and all looked normal. The truck drives like it has lockers in the diffs when in 4wd. If I raise the truck with torsion bar cams, do I need to get a dropped pitman arm and idler arm? Any suggestions would be great, John.

 

I have seen this happen on a truck that had differnt gears in the axles. They have to be the same and the tires have to be the same size. Now if yours are all the same it could be too much angle on the cv jonts or your ring and pionion is too tight or something is lose or bent in you system. Did you brake only one cv axle or more. Did it brake or just come apart. what was happening when it broke. did the shaft brake or just the berings inside of it.

 

I mistakenly said the left and right stub shafts are equal length, the right is longer but there is no vacuum shifter. The left and right CV shafts are equal length. Only the right shaft inner CV comes apart, the three rollers and tri-cross gets pulled-out. It has happend cruising straight on the freeway at 65mph in 4 hi, it has happend in 4 low at 1-5 mph in deep mud while turning sharply and also in low while going straight. I bought the truck used and wonder if it has been wrecked in the right front, the right tire sticks out of the wheelwell 1 1/2" . The truck tracks fine and doesn't pull either direction. The engine and differential assembly are not centered in the frame, but I could not find a way to adjust that[which is why the spacer was installed on the right CV] . I will check the ring/pinion ratios, I've only had the front diff apart before. Tires are all 235/75/15, tire to wheelwell spacing looks about the same left to right. Thank you, John.

 

Took apart front and rear diff covers , both gearsets are 3.55 . While up in the air the front tires turn with little resistance, a lot less than in the past. I wonder if the previous owner never used 4wd ? It definitely seems to be binding in 4wd while turning. Driving in low or high it acts like it has lockers for diffs , shakes, shimmies, doesn't want to turn. I have checked all suspension parts, all seems good, I measured alignment and position then reset what I could to within specs . I don't know how to reposition the engine/front axle assembly { I can't find where you would adjust it] and I don't know if it needs to be repositioned. Is the engine/axle/brackets supposed to be offset ? John.