I just took a look at DRM and Tex's info, both Toyota drivers. I do appreciate your honesty guys. You are both defintiley a cut above the type of baiter who would not give his real info. Things must be pretty boring in the Toyota area for you to be here in the Jeep section.
I fourwheel with the local Toyota club a lot (Mn Toyx4s,
www.off-road.com/~mntoyx4 -- check out their trail reports page, it's one of the best), and I've got a lot of friends in that club - some of whom I help work on their trucks. I've seen lots of Toy axles break, particularly in the birfield area. I've seen far more birfields break than Dana 30 U-joints, but my personal experience is pretty much in line with Warn's findings - I think they are about the same strength. I think the reason I see less dana 30 breakage is because I see a lot more Toyotas with front lockers and 35" tires than I see Jeeps with 35s and a front locker on stock axles. Most Jeep guys upgrade when they go to a front locker and anything bigger than a 33" tire.
IMHO Warn is by far the most reputable manufactuer of 4x4 parts, calling their data into question is kind of silly. No one else has ever devised the proper equipment or done a scientific study of this kind before. Their Data is much more conclusive than anyone's personal feelings. If Warn says that a Toy birfield is only as strong as a 260 Ujoint, you had better be believe they can prove it - or Toyota would have already sued them. The Toy ring gear is only .3" bigger than a Dana 30 ring gear, and the Toy 3rd member is not as rigid as the Dana center section, most likley making this front end issue a wash.
A couple of other comments on the practicality of this swap: I kind of doubt that the Toy frame rails are 28" on center, which means that a Toy axle would probably have to be narrowed or the springs would have to be outboarded. It would be a lot easier to do a Dana 44 in this respect. I also wouldn't make the backwards step from an open knuckle Dana 30 to a closed knuckle Toy front end. The turning radius is not as good on the Toy front ends and they tend to leak in more water, both due to the closed knuckle design. I won't even go into how expensive it is to work on Toy brakes, but rebuilt calipers or wheel cylinders for a Jeep are usually around $15 to $20.
How much does my Jeep weigh? About 4500lbs. T-18, Dana 20, Dana 44s front and rear, 258, heavy bumpers, winch, full cage, on board air, all of this adds up. CJ7s start at 3500 lbs when they have the lighter stock compnenets.
Toyota axles work very well in Toyota trucks, but they aren't the best choice for a Jeep. Not even if they are free. If they were I'd have them in my Jeep. I had access to many sets of Toy axles with 4.10 gears for free or nearly so when I was doing my buildup, but I passed on them for many good reasons.
The more knowledgable Toy owners have been e-mailing me with questions about installing Dana 44 front ends from Wagoneers. Peer pressure from other toyota owners seems to prevent them from making this upgrade, and I think this whole thread is somehow turned into backlash from that.
This is going to be my last post on this thread. I'm not going to waste my time debating this any further.
John Nutter
ORC JEEP staff