Single piece axle?
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EMS off-road sell a single passenger side axle shaft. Might be worth fixing the issue at hand that causing your problems. Ive been running 37" BFGs on my OE dana 44 front axle without a lot of problems. Just switch to the posi loc (which you mentioned) and only run Spicer brand u joints.
If the problem is with the coupling of the axle shafts, just spend a little time getting it adjusted so it engages smooth when you need it!
If the problem is with the coupling of the axle shafts, just spend a little time getting it adjusted so it engages smooth when you need it!