Kurt,
Sorry to hear about the rear end going out. i didn't see where we established which rear end you had? Corporate or ?
Unless the technology and design criteria changed you would be better served with an aftermarket ring/pinion and welding as mentioned by Mike. My opinion, I have an ass to.:rofl:
My opinion is based on the following. If you have a corporate rear end there isn't much that's stronger than what you have in terms of the lim slip. The other options offered work more consistantly but aren't much better in terms of strenght IMHO. That being said i would weld it up if you don't haul loads and turn left and right.
As for the ring gear... Generally a factory gear is physically harder to create length of service, this is it's performance downfall, it has little give when you beat on it. It'll break. A performance gear is not as hard and will give a little, "flexing" of sorts similiar to the Golden Gate Bridge, it doesn't fight the earthquake, it gives with it and lives to see another day. I build structures that sit on monster ball bearings so they move with the quake versus being shaken to the ground, same type of thing. You can still break the gear but it'll take a more effort and subsequently wear faster.
Lastly... perhaps you just wore it out? Have you looked at the surfaces to see where it's landing? Is it perhaps whining a little?