What can we do to upgrade our axles?
I have an 03 D60/Sterling 10.5 I'll be running 42"s and plan on abusing it.
Is there anything I can do to beef it up? Any junk yard unit bearing conversions instead of paying 2000$?

 

Id think the d60 and 10.5 cold take quite a woopin and ya should be fine.

 

How about a cheap place for replacement axle shafts/stub shafts?

 

It has been my experience so far that the words cheap and superduty don't go very well together! Lol. However, rockauto.com has some pretty good prices on most things.

 

Well I'm hoping for a good price on used shafts.

 

For used you could check car-parts.com

 

that likely are not any better than what you have. Honestly difficult to break a free floating axle shaft, they don't support the truck, just transmit the torque. Its not like a 9 inch where the shaft is cantilevered out transmitting torque wile also supporting the truck. I once broke a 31 spline 9 inch axle on a 77 f150 right beside the wheel bearing - stopped her in its tracks. wheel came completely off with the brake drum. Sucks when that happens.

 

The used shafts would be spares. They may be strong but I'll be hopping on rocks with 42" tires. Seeing 2.5 ton rockwells snap does not give me confidence in my tons