I would go up to 40s or 42s for the tons, 37s were it for the Toyota axles but those wont work on the tons cause of diff clearance like you said. My Toy axles are pretty much as beefed up as possible, beefing up the transfer case would be next.
Like I said, im just playing around with the idea, maybe I'll just rebuild the busted case with a chromo output shaft and swap it back in and see if that helps. But that's just more $$ dumped into Toyota stuff, so no biggy right
I would hope that with an atlas and tons the weak point would be the u joints, but I also hoped that for this current setup lol