Maybe I missed something, but the thread started out with a mention of taking out a dana 28 and installing a dana 30. And somehow it went straight to 1 ton running gear. I have a Bronco II with a 5.0L swap, dual t-cases and 35" tires. I have a dana 30 in the front and a 8.8 explorer in the rear. Now I don't think the dana 30 is the best axle for the job, but hanging 1 ton running gear under a truck with 35" tires is over kill with bad ground clearance. 1 ton running gear is designed to carry weight, it has improved torque compacity but most of that huge mass is about carrying a load. Is there a reason why a 44 with 9 or 8.8" dif has not been suggested for this build? It seems like the obvious choice.
The most obvious choice would actually be a D35 & 8.8" from an Explorer. The D35 is easily 95% of the D44's strength, the 8.8" stock-for-stock, matches quite well with the 9" too.
If all the time and effort is to be put forth into a full-fledged axle swap, going straight to one-tons would make the most sense, as the D44/9 (JMHO) don't have a whole lot to offer over the D35/8.8", which just bolt right in (well, the 8.8 needs leaf perches welded to it).
If "solid axle" is simply your thing, then maybe... but you can set up the TTB suspension to take you pretty much anywhere a D44 solid axle would take you (and then some, if you like to do it going fast). There is tons and tons of info around here for unlocking the mysteries about the TTB that tend to intimidate many.
With 35" tires, I do think the D35 & 8.8" would be plenty enough, unless he wants to be able to plant the throttle of that 5.0L on the floor constantly, in which case I would still suggest the D60/10.25".