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I think the general perspective on axle strength has changed over the years. Everybody thinks they need a D60 because all of the cool kids have them. With that saying I do have a D60 but can justify it. Heavy vehicle, 39.5" tires, locker, hard trails....and broke the stock 10-bolt front a couple of times with only 35" radials and a limited slip, so no way it would last with bigger tires and a locker. I also know guys that have upgraded from a D30, to D44, up to a D60 with chromo shafts but have never broken anything and really don't wheel that often or that hard.
My experience on strength.
6,000 lb. K5 Blazer with low horsepower, auto trans, and locker. 13/38-16 Swampers (really small for a "38"). Broke a stock necked down inner, broke two stock outers, and found a 3rd outer twisted. Axle was from a '77 farm truck so a lot of wear and tear over the years. Replaced inners with non-necked Spicers with no issues since. Finally replaced the outers with Yukon 35 splines with no issues since, and have ran non-greasable Spicer u-joints since the beginning with no issues. Like to think I know when to get off the gas but it does get used hard and has ran trails like Widowmaker in Slade many times.
78Buford runs a Ford D60 under his F-250. That thing weighed 7,000 lbs. for years before going on a diet and has ran 13/38 and now 42x15 Swampers for many years. Current engine is a built 460 with an estimated 550 ft-lbs. of torque with an auto and no crazy low gearing. This thing has gotten beat on hard for years. He ran Spicer inners and 35-spline outers with Spicer joints for years. Finally broke a stub but the spindle bearing was shot and making a groove in the stub where it broke. The u-joint holes were starting to egg out a little also. They were replaced with Yukon inners and outers with some sort of high strength joints. These have survived for years with no issue.
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