I have the 94, no disconnect, and have for the life of me, wondered who was the genious who came up with the vacuum disconnect? really what purpose did it serve, and saving wear and tear or increased gas milege, is a generic, I dont know crap answer

any Jeep engineers around, im waiting

 

go with the 94 and get some shafts from a 95+ with abs or 97-99 hp d30 with the bigger u joints the disconnect style is garbage but either way i wouldnt weld the spiders on a d30

 

do not get the disconnect. iv been having tons of problems breaking stuff because it weakens the passenger side. i hate it and im actually buying a new axle just to get rid of it.

 

breaking stuff and disconnects not working is a 50/50 chanxe it can go either way i run a 89 hp dana 30 on 38s have had no issue alot of these issue have to do with driving habits and previoius maintenance on parts

 

I already have both axles. I'm just trying to figure out which axle I want to put under it. I really like the fact that I can weld the disconnect and still have good turning capabilities. I don't plan on running tires larger than 33's if that. This is a beater rig, just something to satisfy me until I get the cash to build something how I want it. I don't want to sink cash into it.

 

Ive got an 89 HP disco 30. Never had a problem in 80K that Ive owned it. Wheeled a fair amount on 32s. When I took it apart to do u-joints one time....scared the hell out of me, because the axle on PS where it goes together is about the size of your finger!

That said, a lot of guys like the disco housing because of the big cast piece where the upper control arm attaches. So, use the disco D30, but block off the vacuum housing and use the one piece axle from the new axle. You just need a different seal on that side.
Thats what Im going to do as soon as I get regeared to 4.10.