Cool swap! Is that the gc front dress,fan and shroud? Also i missed what year tj you have?
On the axle swap issue consider a super 35 kit over the 44hd. Probably a better choice.
On the transfercase side an sye is cheaper for the 231 and it is an inch or so shorter.wider chain and 6 pinion planetary is a simple junkyard swap.but a 242 would be cool for launching that tj.awd and a 5.9 will throw you back hard compared to a 2.5
1997 TJ... i cut down the 2.5 fan shroud and then heated and reshaped it to fit the fan. It is an 11 blade ford fan and A jeep 4.0 heavy duty fan clutch. I wanted a mechnical fan.
I have the 231 and the 242 tcase. Most of my driving is on the street. If I go to MOAB i would stay on the easier trails, if there is such a thing. So i decided in the 242...
I am still back and forth on the rear axle choices.