they're really called core plugs, they're necessary during the sand casting process.

 

I did not know that.
Thank you for clearing that up.

 

The Rovers North magazine is written by people who're just as susceptible to perpetuating myths as anyone else.

 

Well said, well said.

 

Further research (ARB website) gave me some hints as to the answer to my original question. They list the diameter & number of splines for all the axles for which they make lockers. I understand there would be differences in alloys & forging methods that would complicate this, but if we assume that material strength is equal, then diameter should show relative strength. I've listed the axles in order of diameter.

Dana 30, 27 spline, diameter-29.5mm
Chrysler 8.25, 29 spline, diameter-30.7mm
LR 24 spline, diameter-31.5mm
Dana 44, 30-35 spline, diameter-33.3mm
Ford 9", 28 spline, diameter-33.5mm
Dana 60, 35 spline, diameter-38.1

 

i think you meant to say dana 44

 

I did & I fixed it, Thanks!

 

no prob, good info..I didnt think about looking on the arb site

 

i live near a big foundry that heat treats metal, makes metal etc. Is it possible to take existing axle shafts and heat treat them to 4340 chomoly? or is that just a whole different metal. Or simply make them stronger by thru hardening rather than case hardening. Any thoughts?

 

No, chromoly is a different metal with a different chemical makeup. Hardening would make them harder, but would also make them more brittle. It is very unlikely that you will improve the axles by having someone change the temper.


Frankly though, I've never seen a broken D2 axle. ShadeTree runs stock axles in his D2 which has 4.10 gears and an LS swap, and from what he's told me he's pretty rough on them. Axle shafts are not the D2s weak point.