Green, your experience with the D30 is interesting to me. I run the original HP D30 on my 94 YJ, only I've replaced the passengerside 2-piece axleshaft with a one piece axleshaft; in fact I've replaced the original axleshafts with a beefier alloy to increase the axleshaft strength. I also installed the 297X u-joints. And, I have an ARB Locker in the D30 axle. The ring & pinion gears for both axles are 1:4.56. I have a Terra 60R (1 ton rated) rear axle. My Jeep buddies tell me that the 4.56 gears are now my weak-link in the engine-to-wheel torque distribution; Like you apparently did, I attempt to be smart about using the front locker, and use it sparingly. The HP D30 has held up effectively over many years on many difficult trails. I'm starting to believe my front axle is a little more tougher than I thought, and use the front locker more
frequently. The reverse-cut HP D30 is by design considerably stronger than the D30 axles used on pre-YJ Jeeps, at least, it's reported to be stronger. I'd always planned on upgrading the front axle to D44 or a D60. At this point, I'm thinking of staying with the HP D30. Seems to be working well, and I like the greater ground clearance with the little pumpkin on extremely rocky trails. However, It does make for a lighter front end; it's a lot like driving a farm tractor sometimes when climbing some of the monolithic rocks down here in the Rockies. <img src="/forums/images/graemlins/cheers.gif" alt="" />