4 Wheel Drive/SUVs: 4x4 alxes, stock dana, dana 44

Question
whats the biggest tire size that should be used with 1/2 ton axle's?  

Answer
George,

This depends on the size motor, and how heavy your throttle foot is.  I run 35x12.50x15 Baja Claws on my Jeep, and it had a Dana 35 in the rear, and still has the stock Dana 30 in the front.  I have seen people run 38" tires with few problems in the smaller rigs, but they tend to drive slow, pick good lines, and don't get the tires in a bind.  I finally went with a Ford 9" in the rear, as the Dana 30 has a problem with weak axle tubes, and bend.  This can be corrected by welding in some braces, or gussets.  My problem was that by the time I found this out my tubes were already bent.  I, usually replace worn or broken components with the strongest, and heaviest that I can afford at the time.  This seems to be a standard practice with everyone that drives a true off-road 4x4.  Use what you have, and upgrade when you can.  

I would find out what differentials you have, and go from there.  If you are running Dana 44's or larger, then you should have no problems with 35's, unless you're running a lot of power and like to use it.  Another factor, is, if you like to jump the rig and run it hard.

Most drivers end up with Ford 9", or Dana 60s if they run extreme tires and run the rigs hard.

It all boils down to your experience, and how hard you are on the vehicle.

Carl