Rotations of one axis close to 90 really sounds like you're getting into gimbal lock territory. In that circumstance, information is being lost in calculation where one axis (and it's rotational information) is rotated into another. E.g. 90 Z rotation means X and Y axes coincide. A related example is when conforming clothing can jump off a figure which has had its body rotated about the Y axis by exactly 180 degrees. Change it to 179.999 and it's fine, 180.000000 and the clothing decides you haven't rotated the figure at all. In your case, if the morphs are being controlled by one of the limb rotations, you could try interposing a valueParm or dummy targetGeom with no deltas as an intermediary. I.e. joint controls dummy, dummy controls morph, then see whether a slight offset in the dummy can counteract the loss of information when the joint gets to 90 degress or change the angle the problem happens at.

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