You probably have the explorer disc brakes? Thats a nice setup, I have one sitting in my garage I just regeared to 4.56. Keep an eye on your brakelines: I was going to run a stainless flex hose with a t at the end to the top of the pumpkin, two steel hard lines out towards each backing plate, and a stainless flex hose going to each caliper. You have to have the flex hose to the caliper because they float on slide pins. okay i'll look at it, and yeah its a 97 ex brakes, its gonna be awesome. and my plan is to eventually regear to 4.56, i just wonder what the 4.0, a4ld, 4.56's and 30's for now, will get gas milage wise. and then later on at 33's what will my economy be, i gotta be able to afford to drive it daily
As far the the build-up goes, The aussie your getting is a "lunchbox" type that replaces your side gears, correct? If so, there is no reason you can't go ahead and set-up your gears, you would have your shafts (and therefore your aussie) out at that time anyway.this is because i hate laying under that truck in my driveway to do it. i'd rather just build it and on the table and mount it up finished.
Watch for the cross shaft hitting the ring gear when you remove it. On my 4.56, it did, I ground a tooth for clearance. I'm not sure if your 4.10 will. Yukon's install guide has the torque, backlash, and preload specs for you.
4.10's shouldn't becasue they are factory gears
As far as cool stuff, I've had my eye on a diff cover by Ruffstuff Specialties. Super beefy 3/8" cover, 1/2" mounting flange. Ruffstuff is a vendor here, and they offer a 10% discount to TRS users. i got my ruffstuff thru a jeeper here local that was building an 8.8 for his tj, but then sold his tj and 8.8, not the cover, and got a rig on d60's!!! You can get upgraded rotors and pads I'm sure. C-clip eliminators. Yada yada yada
edit: I need to read the whole thread before I post , huh?
