I don't agree with your D30 opinion, you can build a D30 to easly handle 35" tires without much money or effort. The D35 is another story, I wouldn't put a dime in that. Going ford 8.8 with c-clip eliminator and cromo shafts with whatever locker you prefer is a good choice for the rear as is the D60 or Ford 9". If you really feel you need a bigger front go D60 front and rear.
The D30 and and 35 are what are in it now. I just know that they are weak and would like to up grade the strength a little on a good size budget. It only has the 2.5 so its not like im pumping a shit tone of torque
That's where we disagree, the high pinion D30 is a quite strong unit. I wheel with guys who do serious rock crawling running 35" tires and lockers with a built D30. Stronger axles, larger u-joints, some even truss the top and you're good to go. You would have a tough time breaking it with a 2.5. But as I said, there are those who demand 1 tons, seems like overkill to me unless you're really a beater, but to each their own.
Btw I broke my D35 in under 2000 miles with 35" tires
I agree with them about the D30, I've had a built 30 running 38's and 4.0 and never had issues but I'm not a beater on my jeeps, I have 38/15.50 now and also a built D30. And if your running 32's with 2.5 I think you would be ok with just upgrading. But definitely go 8.8 in rear.
Yeah, that D30 should handle the 2.5l and 32s just fine. If you really feel like it, you could throw some XJ/TJ shafts in there too to delete the CAD system and get bigger u-joints.
While everyone recommends really building the axle with alloy shafts and stuff, I personally think its not a great idea. Leave the shafts and u-joints as the weak point. I've seen upgraded shafts not break when they should, and it explodes the ring gear, pinion, or spiders instead.
92 YJ, 4.0, 5" BDS springs, 1" booms, 1" BL, 35x12.50x15 MTZ's, Ford 8.8 with LSD, 4.10 gears. It's never done though.
I ran the stock 30 in the front of mine for years on 35 s with a lock right the only thing I broke was the u joints . I since went to a 44 with 37 s . You'll be fine with the 30, change the rear don't waste the money to build it.spent the $ on chromoly shaft for the 35 and the ring and pinion exploded