bob91yj
Resident **************
Other than the availability of deeper gears, I don't think the Rubicon front axle is worth starting over for.
Just for a reference point, my rock crawler is still running a D30, admittedly a High Pinion D30 so it is working the correct side of the gears (4.88's), and a Loc-Rite lunch box locker. It's never given me a moments trouble. I have upgraded the shafts (Cr-Mo) and u-joints (CTM's) over the years. I've broken one axle shaft/u-joint (stock TJ shaft and 297x joint, both failures at the same time, I suspect the U-joint went first) in the hundreds of miles I have put on it in the rocks.
I also agree that the 4:1 tcase in the Rubicons is too low for most expedition type rigs. It's great in the rocks, on expedition type trails I find myself constantly shifting between 4L and 4H to maintain a decent pace.
For what it's worth, I'm not a fan of the AiRock suspensions at all. Suspension shouldn't be that complicated on an off road vehicle IMO.
Truth be told, I like the leaf springs on my YJ the best. They are stupid simple, and with some tuned Fox 2.0 shocks, it handles most terrain every bit as well as the bling link suspension on my LJ.
I've tried Rancho 9000's on both of my Jeep's, couldn't get them off soon enough in either application. The adjustment window for each setting is too tight, shock is never set right for the terrain I was in. I also found that they overheated and faded to almost useless in 5-10 minutes of hard running. I've got the Fox's on my rock crawler, and I went to Bilstein 7100's with remotes on the LJ. Both the Fox and the Bilstein's are completely tunable via shim stacks, hydraulic fluid and nitrogen pressure. Last shocks I'll ever buy for either of those rigs.
Just for a reference point, my rock crawler is still running a D30, admittedly a High Pinion D30 so it is working the correct side of the gears (4.88's), and a Loc-Rite lunch box locker. It's never given me a moments trouble. I have upgraded the shafts (Cr-Mo) and u-joints (CTM's) over the years. I've broken one axle shaft/u-joint (stock TJ shaft and 297x joint, both failures at the same time, I suspect the U-joint went first) in the hundreds of miles I have put on it in the rocks.

I also agree that the 4:1 tcase in the Rubicons is too low for most expedition type rigs. It's great in the rocks, on expedition type trails I find myself constantly shifting between 4L and 4H to maintain a decent pace.
For what it's worth, I'm not a fan of the AiRock suspensions at all. Suspension shouldn't be that complicated on an off road vehicle IMO.
Truth be told, I like the leaf springs on my YJ the best. They are stupid simple, and with some tuned Fox 2.0 shocks, it handles most terrain every bit as well as the bling link suspension on my LJ.
I've tried Rancho 9000's on both of my Jeep's, couldn't get them off soon enough in either application. The adjustment window for each setting is too tight, shock is never set right for the terrain I was in. I also found that they overheated and faded to almost useless in 5-10 minutes of hard running. I've got the Fox's on my rock crawler, and I went to Bilstein 7100's with remotes on the LJ. Both the Fox and the Bilstein's are completely tunable via shim stacks, hydraulic fluid and nitrogen pressure. Last shocks I'll ever buy for either of those rigs.