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are you using aftermarket axles and/or cv's? i had a bad experience with jobber axles - softer steel than oem, improper cv articulation, improper fit in transmission flanges due to wrong dust caps. bad steel might be what is causing the splines to shear. or, if after market cv's (or undersized aftermarket axles) any play between cv and axle due to improper tolerances might be causing your shear.
i got good results by buying a used oem axle/cv combo from a wrecker for about the same price as new from a jobber.
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