Ok... I still have an unresolved rear end issue.
The 14 bolt is of course the best option, but it's a logistical nightmare in comparison to fixing the 10 bolt. I'm not in a position to go off road a lot right now, and since this is my daily driver I'm obviously much more concerned with whether it moves or not than whether my axles will stand up to trail abuse.
After speaking to a reputable shop, it would cost about the same to install a 14 bolt (including the cost of the axle and other parts) as it would to rebuild the 10 bolt.
I know I've previously described the symptoms, here's a recap of the main points:
When I go around curves at normal driving speed the rear end pops and clicks like crazy, making grinding noises, vibrates, etc...
It has a factory locker installed (G80/GU80) with 3:08 gears (terrible)
I must switch this thing to an open carrier immediately. I've found good parts, but I don't know how many splines I have and would prefer to know before taking it apart or starting this project at all.
I know this would be a major guess on everyone's part, but in your opinions, would the axles be reuable. Is what I'm experiencing simply a problem with the crappy locker? I've seen mention of these exact symptoms when those lockers start to die.
I figure I'd replace the carrier with an open carrier, spider gears, and ring and pinion while I'm at it since the 3:08's suck big time.
I'm not looking to get 100K miles + out of this rebuild, simply looking to make it street reliable.
Thanks,
-JP