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2" lift 31" tires and d30/d35 axles and nowhere close to being hard on it.. IMO your good to go as is. Be happy don't worry. If you must do something, work on wheel backspacing and bump stops.
I used this guy for the last 4 axles I built. Revolution gears are second to none and gave a really good pattern every-time. Yukon's used to be my go to but not anymore.
http://rwkhaussupply.com/jeep-specific/jeep-xj.html
One thing you might want to take a look at is the door button switch. Take it out and inspect it. pay close attention to the connectors. those wires that connect to it are small and can short/break easily. This can cause all sorts of BS with the buzzer and interior lights.
I had the same issue as you only mine was P0306. Didn't do the seafoam or wrap the fuel rail, but everything else. Turned out it was the wire harness to #6 injector. Replaced all the injector pigtails with a kit I got from Amazon. Hasn't come back yet.. 3 months.
ok, you say 33's w/3.55 gearing w/AW4 (auto) = 3k rpm at 55mph?
Something wrong here... if the above is correct you need the transmission looked at... it's slip'n
I hope your not thinking of just doing the "rear end". Unless you have a 2 wheel drive. I posted this a while ago and it might just be what your looking for.
I am using the JK wheels with the standard stock, more street orientated tires on a 3.5" OME lift, 1.25 spacers/adapters (4.5 to 5.5)...
Think of it like this....
It's in the place where if have to ask you'll never know. If you know then you don't have to ask..
Extra points for anyone who can tell me where I got that from....
Someone will correct me if I'm wrong here but, I'm pretty sure the housing is pretty much the same on all XJ D30's ABS or not. You can even use the low pinon from the 2000 2001 if low pinon vs Hi pinon isnt an issue with you. Difference is low pinon will require the correct gear set.
I've built and wheeled all of the configs you list above at one time or another. IMO 33" and 4.56 are the way to go assuming the following.
Basically a somewhat stock rig ( yeah. this includes armor) using a d30 and cry 8.25 and being used as a wheeler/daily driver. I like the 4.88's for a...
Buy or make something like this and get those shocks out of the way of potential damage. Just make sure the shocks aren't being used as the bottoming stops.
https://jksmfg.com/i-9052781-fab-rear-axle-shock-mount.html
Having done a number of gear sets I can say I have seen this before. 2 things come to mind here. Bolts need to be the correct length and shouldered for shear strength. Many aftermarket carriers have different dimensions on the gear shelf . I had an ARB once where we measured the bolt (which came...