What is the largest tire size I should run on my ton axles?
You can pretty reliably run 35 inch tires on ton axles. The rear axle is very strong, however the weak Dana 44 hybrid front axle is not. Its weak point is the unitized hub assembly. If you run tires larger than 35s, or if you wheel with 35s, you might be replacing hub assemblies frequently (once a year or more). There are lifetime warrantied ones you can get, and since the assemblies are expensive, this is the only way to go. You can usually run a 37 inch tire on ton axles without much worry but you will need to learn your limits. What kills these axles is when you start spinning the tires and then they hook up finally, you can snap the small front axle shaft very easily. If you plan to run large tires at some point, try to buy a ton instead, or just start saving up for new axles. Having a big truck with big tires is no fun if you cant use it because you are afraid your axles will break in half.