I was thinking that I could have sheared some of the splines off the end of one of the axle shafts, causing it to bind/pop/spin in the carrier when loaded in one direction. Wouldnt it make noise turning both directions if it were a spider gear? In a straight line or turning right its quiet. I havent had time to pull anything apart yet, even picked up a rental (Dodge 1500 quad-cab 4x4 <img src="/forums/images/graemlins/smile.gif" alt="" />) since I wont have an opportunity to mess with for at least a week and its my daily driver. Its a little cold/wet/icy to take the bikes out.

But, assuming it is the axle/diff/anything having to do with the d35, I'm thinking I should upgrade to a d44 and more appropriate gearing. I found some OEM axles here:
http://www.jeepsareus.com/Merchant2...Code=JAU&Category_Code=Wrangler1

As much as I would like to get the pair of d44's for the rubicon, I think I'm going to be stuck just getting a single open diff d44 rear with 3.73 gearing. I know you have to swap carriers in the d35 if you go above/below 3.55, but I'm not sure about the d30 up front. Will a front d30 with 3.07 take 3.73 without having to swap the carrier?

Any recommendations on other sources for bolt-in axles (barring the usual trek through the junkyard)? I need something bolt-in that wont break the bank.

Actually, now that I think about it more, it could very well be a gear, I've noticed over the past several months that there has been a lot of play when rotating the driveshaft by hand (not lateral, just rotational), and its been making a more pronounced whine over time. I was hoping to stay away from diff internals, since I know very little about the art of setting them up properly, and dont want to learn on my daily driver.

Maybe santa will be nice this year and leave a Bowler Wildcat on my front lawn.
http://video.google.com/videoplay?docid=8292520021453710550