JKcommerce,
No offense but, I'm not sure how you will accomplish this without spending any money. The ARB and gears in your D30 are worth some money, but the value is nowhere near a 60.
If you do a junkyard swap, you will have width and bolt pattern issues to deal with and the finished rig may not be street legal to run in your area.

IMO, a Rubi Front 44 with upgraded shafts, gears and CTM ujoints and a RockJock 60 rear would be an awesome combo. Front 60's are the real cost of upgrading to one tons.

 

Can you run a 60 rear and 44 front with no issues?

 

Currie has the proper parts to do it right it looks like. Figure $1060 plus shipping for the axle brackets etc. from them it looks like. I've seen drastic differences in prices for Dana 60, 70 & 80 on Craigslist. Anywhere from $100 just get it out my garage to $1500 its plated in Blingtainum kinda thing.

From my perspective the positive thing about going with these axles besides the size and strength is the sheer amount of used 8 lug wheels and tires available for dirt cheap on Craigslist. Having a JK with a roughly 6-8 inch wider stance would be nice as well.

One thing to look into would be the axles out of a late model Ram truck because if I'm not mistaken they might have some of the same sensors and plus they have the rear disc setup as well and the front diff is left hand like the JK.

 

why couldnt you? people have been running 1 tons in the back and 1/2 tons in the front for years.

 

Yep. It's called a 3/4 ton and it's done all the time.

 

Dana 60 REARS are a dime a dozen and can be found in numerous 70s and 80s trucks and full size vans. The FRONTS are a different story and you'll be lucky to find a used front axle for under $1000- and that will still need a rebuild, gears, brakes, etc.
Sometimes you can find a complete donor rig with a 14 bolt/60/70 rear and 60 front without an engine or trans for cheap. The Ford high pinion front 60's are the most sought after axles as thy have a less severe front pinion angle and are easier on driveshaft angles. Before going full width (or many other mods) always check your state and local laws for what is legal on a street rig in your area.

 

I'm in the process of swapping now.
The axles that work with the least amount of hassle are from 2005-2008 Ford Super Duty.
I had to change the brake master cylinder and power booster because the factory unit did not move enough fluid to gain a strong pedal. there is a guy that did the swap in a JKU and he made a bunch of great videos and he included a list of all of the parts he had to change.
heres a link to just one of his videos. He runs the youtube channel "JK Gears and Gadgets"
there are several vieos of the progression of his swap. I hope this helps