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I ran them for a year and a half 3.5" 7 leaf pack (IR-X3RSP) with the +1" shackles (IR-X_1LS) This is the combo that came with their 5.5" long arm kit. They flexed good had a nice ride. When I pulled and sold them they still sat within a 3/8" of the same ride height as when I installed them.
I've done this to a 79 D44. Drill out the plug welds then use a big hammer and hit the wedge on the short side tube first. Once thats out I used a piece of round stock thru the diff and knocked the long tube out.
I have a 79hp 44 with the cast wedges. I re tubed mine for my application and noticed that the tube going into the housing is only .250" wall. Don't know if you planned on doing a truss but you may want to look into it.
The revolutionary caster adjuster sucks. Mine bent after a year on the jeep. As for the three bolts holding the long arms on each side I didn't even try to risk that one I just welded mine on. I'll be cutting the caster thing off and basically copy TnTs setup to fix the issue.
Different setups apply different amounts of stress to individual parts. I'm pointing out that the instances of the 10mm bolt breaking you gave are from an entirely different setup.
The rear springs have been holding up quite well. The only complaint I would have with the 5.5" kit is the rear springs are a 3.5" pack with 1.5" longer shackle. Makes for a better ride but the rear sits lower than the front. But once you relocate the rear shackle mounts to fix the shackle angle...