I agree with Jim that the second cracked bell housing is talking pretty loud that someone not something is going on.
Check the ratios, pull the covers do the math, ring gear divided by pinion. Verify before having a cow.
So far you have been very calm about the whole thing.
Next is to bring it to a shop that has a stellar rep and pay what they want to go through it. Sounds like the jeep has some good stuff ARBs SYE kits...you have good money going for some bad work. Nip that.

SD

both shops are highly regarded in my area (kentucky). one deals only with jeeps, and the other specializes in 4x4's. the second of the two is way more $$$. it doesn't do any good to get pissed off, but it sure as hell doesn't make sleep any better either.

John wrote:

"As you installed a slip-yoke eliminator, was the drive shaft length checked?

Could the drive shaft be too long and bottoming out to cause undue stress? "

After thinking about John's post for a while, I can see this to possibly be the problem..

If the shaft is too long it will bottom out poking the transfercase and the tranny UP and the tranny mount could cause extreme torque on the bell housing.. As the housing is near the middle of the front and rear mounts that poking from the rear could cause the cracks to occur. I think I would check that length real good.

Good thinking John.

Big Jim <img src="/forums/images/graemlins/pfft.gif" alt="" />

Just got in at the bottom end of this. I agree with Jim. When I read this through, it caught my eye.

Did that eliminator kit change the output length of your X-case?

Oh, and what part KY are you from?

If I were having this problem, and I thought that it had anything to do with my driveshaft (and I think it does)...I would give the folks over at Tom Woods (www.4xshaft.com or 1-877-4xShaft -- 1-877-497-4238) a call. They know a bunch about these kinds of problems.

Measure the shaft you currently have. Give Tom a call and give them your information: what engine, trans, xfer case, SYE, rearend and current shaft length. Ask what length shaft you should have for your application, compare that to what is currently in your jeep. That will answer a lot of questions. There are many reputable driveshaft vendors out there; however, I've had nothing but good luck w/ Toms stuff.

Ed

i'm from louisville. thanks again for all the input, going start checking over everything and see what turns up. thanks for the help