Your not the only one. Im running a 44 with stock axles and 37's...its only a matter of time before i twist the splines too far. Yikes!I agree with Pthorpe on this one of only adding the sleeves.
I am not one to talk though, as I am still running my D30 with 35's and stock axle shafts.
If you are going to go with large tires, and lots of rock crawling type of stuff, I would find the money to get a D44 at the minimum.
The plan for my Jeep is to buy a D44 or the Currie F9 for the front soon.
I agree with Pthorpe and Todd. With conscious wheeling and no skinny pedal I would say it’d last a while with 35’s. Also depends on your traction and wheeling environment. I’d save the money you would put into your 30 and pocket it for a 44.Our saying at work is "Do It Right The First Time!"
I think that applies here. You can throw good money at a D30 and it is still a D30.
Spend the extra money for the 44 or something with more beef if you are going to being crawling in big rocks.