How much time do you think it would take without using AIR? I'm thinking about take a few days vacation from work and doing it. I'm guessing each axle take about 1/2 day to swap out?

Are there any major PITA items that could set it back pretty bad?

Yeah about 1-1.5 days, with hand tools. If new axels are same type as old. only real issues are going to be rust and broken bolts.

Why are you swapping the axles? New gear ratios? Stronger axles? Wanted to paint them?
I put new axles when doing a 2WD to 4WD swap in a weekend but I changed everything including transmission but I did use air tools.

well its sort of a chain reaction.

I was thinking about going to 4.10's and getting an 8.8 for the rear with disc and lsd. Then I changed my mind and was satisified with what I have.

THEN I discovered my pinion bearings in the front axle is bad. Very grinding in 4x4. Removed the front drive shaft yesterday and 4x4 became silent(= not transfer case).

If its easier to swap out the axle then redo the gears and bearing, I might as well get one with 4.10 and just pull the trigger and do it all?

Advice is very welcome people ! I do have 2 other cars, so I'm not worried about it being un drivable for awhile if need be.

Edit: Crap, now that I think about it, it could still be the transfer case bearings or the pinion bearings. Taking out the drive shaft also removed the torque from the transfercase front yoke.

Normal 2wd - silent
Normal 4x4 - grindy
Removed front drive shaft - 4x4 and 2wd silent

Since I practically had my front axle out of my ZJ when I did my lift, took all of about 2 hours total. Granted, I did one side at a time. And when I was messing with lift blocks for the rear of my XJ (didn't use them at all...), wasted about 2 more hours total, had the axle sitting on a jack only, only the brakes and driveshaft held it in. As long as you don't have any fab in the front, should be able to manage it in 3 hours including brakes.

Since you want to use the 8.8 in the rear, add some time for welding spring perches. But 4 hours or less seems reasonable. Use new U bolts, and just cut the old ones out. No wasted time with rusted parts...

i can do both in one day about 6 to 8 hours but i have done then already. if you have never done this leave your self about 2 complete days to do it that way you can have time and not be rushing to get them done. and start with the rear easier and you can build confidence that way to tackle the front

X2. Just don't get in a hurry.