John
with 4.88's the pinion becomes smaller and the ring gear bigger. So if anyone makes gears for it, it will not be the same strength as the 4.30's. There is no proof that the 100 gears are stronger. Yes the desing is slightly different and I believe I posted pictures before, but there was no indicaction that they are stronger.
Your statement above is not correct. The axle splines are 32 spline, and these you retain when using the 80 gears to regear.
Carl would know about gears, he works for one of the leading suppliers of gears in the country.
105 uses a 80 series axle, 100 uses a semi floater. Yes, the axle shafts are larger and that might be because of the v8.
So what is better. Lugging your tranny to get over rocks when the gear ratio is to big, or a supposed "weaker" gearset? All I can say is that since my crawler box is working on my ShortBus I have not broken a axle or birfield and I have been in places where I would have before. Gearing takes a lot of stress out of the drivetrain since you can drive the same obstacle at lower rmps (so less hp applied to the drivetrain). This migth not be the case with a manual tranny, but with the automatic, you have to get the motor spooled to get going. With lower gears you have more control.
I said this before, there are other parts you are going to break before you break a rear ring and pinion.