please help end this nightmare.

[Organized_Chaos]

Heres the situation...

End of sept 2007 i put a 2.5" rubi express lift into my 1992 Yj 2.5L. in 2008 around feb the syncro gears in the tranny were shot. i drove with it cause it still shifted it just sounded like i was doing so without the clutch ALL the time. Fast forward to two months ago.
u-joint at rear diff explodes - turns super-strength u-joint into what looks like toothpaste coming out of the tube from over heating. (i have pics.)
replace u-joint and straps. explodes 1 week later.
cause=strap bolt broke. figure the tranny is putting too much stress on the bolts.

by some miraculous work of god, a 1993 yj with 2.5l shows up at PICK N' PULL!
straight up GODSEND! so i take the driveshaft, Tranny, T-case, clutch, flywheel, yada yada yada,... etc..
replace some seals, buy new clutch kit and u-joints.
Fast forward to last tuesday at noon.
I'm calling work telling them i'm bleeding the clutch i'll be a couple minutes late for work
Still makes clunking noise when accelerating from stand still. figure the diff gearing is shot from the stress.
>> sunday morning. getting ready to weld up the new exhaust. kinda excited bout getting rid of the noise.
Buddy of mine comes over to get me to tack some stuff while the welders out. happens to crawl under the heep to check clearances for me(Educated at SAIT for heavy duty... knows loads more than i do.)

And i Quote:
Kyle: "hey, Jordan... your axles wrapped..."
Me(jordan): "WTF is that supposed to mean Kyle"
Kyle: "i think you're lucky to be alive."

so the mount that is supposed to mount flat to the top of the spring is rockered much like a hockey skate blade.
the sound was my diff rocking up and down...
now we figure its been doing this for a while cause there's about a 3/16" groove worn, into the axle tubes by the u-bolts... just waiting to break.

A friend of my brother sold me a rear axle (dana 35) with a locker in it a while back before he moved to fort Mac. the only problem is its got 3.83 gears(or whatever comes with the 4.0L)

now i want to use that axle with my gears...

am i out of my mind trying to swap these gears myself? both axles are in my garage sitting on jackstands/blocks open, ready for the swap.

ANY AND ALL HELP IS WELCOME!

OR
Should i weld a couple beeds into the grooves, grind it down flat, cut off and reshape the mounts. weld them back on and hope to hell they work?

[fug]

I don't know that I'd bother swapping your used gears over.   You'll need new bearings etc so you might as well shell out a couple hundred extra and get a new Ring and Pinion as well. 

[hps4evr]

this may be a sign. your YJ is trying to tell you something. they speak to us you know...
its trying to tell you to get it much lower gears and lockers! pull the front end apart too.

[binjeepin]

Welding the tubes will more than likely work as long as you don't blow right through the base metal. Try a down hand technique for the first 2 beads to help avoid this. the root of the problem was probably loose U-bolts and that would explain the sounds and all the carnage that happened to your drive line. I'd check the pinion bearings too as there was probably a fair bit of stress put on it. I agree about just rebuilding the other diff with all new paerts and swap it at a later date. If the spring perches are too worn they can be picked up at nearly any suspension or driveline shop.

[Organized_Chaos]

thanks for the feedback guys. got it up and running.

its safe to drive again.  for now...