I am running 33x12.50 tires in my dana 30 with an aussie locker and the stock shafts with the smaller u joints. I have been on 3 wheelin trips and have yet to break. But my xj is getting lifted more, and i really want to run 35s. Im planning on getting stock tj shafts and putting spicer 760's in them. Is anyone running 35s on a locked 30? How often do you break. And is there anything i can do to lessen the chances of breaking

 

just like any other axle... dont get it bound up

i ran a d30 with a detroit lsd and liked it, you could hold the brake and give it gas to lock it up, otherwise it would open up if it was bound up

 

I already have an aussie locker in it. Ive heard of people welding the u joint caps to the ears of the axle to make it less likely to break, how effective is this

 

At some point its gonna be time do go axle shopping. With 35's you really should start shopping. Your d30 will be the week point and you will always worry about it. So you wont be able to take full advantage of having 35's.

 

yeah, i know. But 35s are the biggest gonna go. And dont have a lot of money, and ive already put a locker in the 30. But mainly, i just dont have the cash for a 44

 

Do this or grind out the shafts and use full circle clips. And if you do choose to weld the caps in place, do it with a large washer and weld it to the shafts over the caps. All you need is a few solid tack welds on each cap. Dont heat it too much or you will ruin the u joint. And remember, it wont be so easy to replace u joints anymore, but chances are you will break a shaft before you wear out a u joint anyway, and spare shafts are cheap and everywhere.

 

What about trying to find some 1541 shafts?

 

AlloyUSA shafts come with full circle clips.
http://www.seriousoffroadproducts.co...ducts_id=75693

10 year warranty too.

 

I've done a few things to help my D30 on 35's.
A selectable locker will extend it's life. I have an ARB. The ARB carrier is stonger than the factory carrier with a lunch box style locker, and leaving the ARB off until needed takes a load off.
Upgraded axle shafts/u-joints. A good truss properly installed, can extend the life of the housing.
Over the years I've trimmed down all the stuff I carry to keep the XJ light. I think that has helped as much as anything else. I've seen a few XJ's that easily weigh a ton more than the stock weight with all the mods and the kitchen sink thrown in. It's been a while since I've weighed mine, but I try to keep it under two tons, lol.

 

Those are nice, but out of my price range, im just thinking a set of used or maybe new 1541 replacement shafts

 

1541 is essentially OEM. I'd grab some Chromo's.

 

I will if i can find some used for cheap. But i dont have the money for new. There is a decent difference in the torgue yeild of 1040 and 1541. And if i could run the stock 1040 with welded ujoints and not break constantly, then the 1541 would break even less, just looking for like 1 set, and keep my factory shafts as spares. Is that a decent plan

 

This only makes it so the caps don't pop out.

 

Take it easy on the skinny and you'll likely be fine.