Ok, so let’s go down the rabbit hole...
I have an 03 XL7 for a parts rig...haven’t magnet confirmed it yet, but from research I have done, seems most likely it has an aluminum front diff.  I am wondering though if it would be worthwhile to go ahead and swap it in, or keep for a Justin Case part.  From some research I have done, even though it is still aluminum, it seems the thought is that those units have a better mounting setup on the snout that can reduce breakage.  Did I misunderstand information, or is this so?  If it isn’t steel, most likely I will definitely keep for just in case, but am wondering if it has any benefit at all over the Kick unit.

Unless your running larger tires the front aluminum is plenty strong on the Kick.  Just check the bolts now and then and make sure they haven't worked their way loose if you have pulled the front end apart recently.

Currently I am just running 235/75/15 tires...of course all of that can change.  I now have a set of 16” XL7 aluminum rims that could find their way on, but I don’t know that I still would ever end up with larger than 30-31” of tire.

I wouldn't worry about it. You can break things if you drop your front diff on a rock, a good skid plate will help avoid that issue.

Otherwise just avoid bouncing your front end a bunch when doing hill climbs.