George, I know where you're coming from. I had an MJ that I swapped a blown D35 out of, and an XJ that I swapped a D44 into. The MJ I put a Chrysler 8.25 into. In hindsight, I probably would have not even swapped in the D44 into my XJ. The XJ already had the 8.25, and I took it out because I thought I needed a D44. I was wrong. There are lots of guys that run the 8.25 REALLY HARD without any problems, the main limiting factor is that you can't go any deeper on gears than 4.56.
What Jeep are you working with here? If it's an XJ, I would seriously consider the Chrysler 8.25. It should be easy to source, as it came in most of the late model XJ's (97+) with the straight 6 engine. It would also eliminate needing to do any fab work on welding on spring perches or shock mounts. You should also be able to source it fairly cheap. On the other hand, you'd probably have to regear it. You'll have a hard time finding it in anything other than 3.55's. In the US, this axle would cost you under $100
If you're in a TJ or YJ, the Ford 8.8 is a very popular swap, very strong and also came with disc brakes and is fairly easy to find here in the US with 4.10's and a factory limited slip. With those options, you'd pay around $200 here. Do some reading though, it does require some work to fit. Not a lot, but you should know what you're getting into. Also, if i remember right, the Ford axle is an inch or two narrower than the Jeep axle. Not huge, but something you need to be aware of. A lot of guys run spacers to bump their wheels back into the center of the wheel wells.
The D44 would run you about $300-400 here in the states, and is also probably going to come with 3.55's and drum brakes. The D44's that came in XJ's were only optioned in 1987, so you're likely looking at a full rebuild as well. Not sure if they came optioned in other years overseas. I don't remember the exact axle shaft diameter difference between the 8.25/D44/8.8, but they're all WAY better than that D35.
I like the idea of putting a Toy axle in, that's thinking outside the box for sure. But here are a few other factors you'll have to consider - The factory locker in the Toy axle is an electronic locker, so you'd have to be able to wire that in. The second issue is that IIRC, the Toy axle will be a 6 bolt pattern, and your Jeep is 5. Bummer there is that means you're looking at the idea of carrying two spares, or using some type of redrilled wheel or large wheel spacers, which isn't ideal. I'm not sure what the WMS to WMS (wheel mounting surface) dimension on a Toy axle is.
Not sure if you're familiar with it, but I spent a lot of time on here:
http://www.naxja.org/forum/ TONS of great info. It's an XJ site, so that's perfect if that's what you're driving, but even if you're not, read in the Modified Tech section on some of the popular axle swaps. Good luck!
