Were you running a hard trail?
I think it started on the Dusy and then I finished it off at Hollister. The front axle would pop occasionally after I got back from the Dusy and I checked everything in the front end without finding the source. Then I took it out to Hollister and it started to pop more often just on the main trails and by the time I was done it sounded like a box of rocks..
I had already "regeared" to a 4.10 and definitely wouldn't put something taller in there as that would just make it weaker. Also 4.10 gives me about 2850rpm at 70mph which feels pretty good to me.
Anyone know where I can find a HP30? I really don't want to bother with my front axle. Also does anyone here have first hand experience runing a HP30, locked, on 35s? I hear it can work, but I also shouldn't have broken my unlocked LP30 so easily. And it's my understanding the weak point on the Dana 30 are the ears on the axles, not the gears. Is this normal for 4.10s?