So CJ is it just the adventure/off road packages that have the cast iron in the 09-10? I remember reading somewhere that the alphas had a few more upgrades besides the torsion bars being beefier, I might be off though.
Great question. I cannot say for sure. All of the 09-10 models I have worked on, have had the Adv. Pak. option...and they have all had the cast iron pumpkins (L5 and V8). I cannot speak for 09-10 base models. I have yet to work on one.
I'm not aware of any Alpha-specific upgrades, other than the torsion bars. As far as I know, its strictly a motor/trans swap. Alphas use all the same radiator, suspension, brakes, etc. The Alpha t-case is slightly different externally, to allow room for the crossover pipe of the exhaust. But, mechanically speaking...the two can be swapped from one to the other. If you put a 5-cyl. t-case into an Alpha, you may have to modify the exhaust where it crosses over. Internally, all BW3393/3394 cases use the same ratios (2.64:1 or 4.03:1). There are subtle differences inside, such as the chain snubber that was added in 08 and the dreaded plastic vs. aluminum shift fork. Not sure when that last item was upgraded, if ever. My 2008 5-cyl AP came with a plastic shift fork.
Some people think the Alphas have different half-shafts but, I personally don't think so. After all...all H3's use the same A-arms, knuckles, and diffs, so technically a different length shaft is not really a valid argument. All H3/Colorado/Canyon shafts interchange with each other and if there is any difference in plunge, its probably a non-issue. I know of several cases of half-shafts pulling out of the pumpkin during sharp corners...on both Alphas and Base models. If a shaft pulls out...its probably more of a quality control issue. I think any change in half-shaft length may have been an attempt by the manufacturer to make them easier to install, and probably has nothing to do with the operational length. You can get ten aftermarket shafts from different sources and probably get ten different lengths, diameters, and plunge ratings. I personally think the whole half-shaft topic has been overthought. Half-shafts are like spark-plugs.
Buy em.
Stick em in.
Wheel em.
Break em.
Repeat.