I finally replaced my weak CV shafts found in ZJ with stronger U-joint axle shafts.
One day I found a pair of old XJ axle shafts with ABS that needed new u-joints on e-bay and $80 and one week later they were mine.
Of course, after hanging out with you guys I couldn't just OEM rebuild them so modding began.
First I had to decide on what u-joints I would want to run with my D30. D30 axle shafts come stock with 5-297x u-joints. There are plenty of choices : OX, CTM, Spices etc but after estimating $$$ of my project "want" got replaced on "need" and "can afford".
For example great Ox u-joint - $130 or even better CTM joint -$205 .
My choice fell on Spicer 5-760x u-joint, used by Superior in their Super 30 kits. It's good affordable ($23 shipped) u-joint that also used in Dana 44 axles and supposedly 20% stronger than the 5-297x style. 760x has the thicker body with even thicker sections near the cross shafts and the cross shafts have more metal in them.
After doing some research on u-joints I've noticed all BIG u-joints come with full circle snap ring vs. just OEM Spicer c-clip. Even Superior replaces c-cips with full circle ring for 760x in their Super kits. Believe it or not these full circle clips add a lot of strength to the joint because they prevent the cap from walking out which is perhaps the most common cause of u-joint failure.
So where would I find snap rings? Our friend- Home depot.
1 3/16" external snap rings would do the trick. Bolts/nuts section, 3rd drawer from the bottom, $0.70 each.
Unfortunately, the stock Spicer outer shaft wasn't designed to accept full circle snap rings. If you compare Warn shaft to the stock Spicer you will see how more material was cut away at the base of the yoke allowing the use of full circle snap ring.