John, most of the recommendations are based on two things; use of the truck at GVW or GCVW and the available oils in the era the truck was built. Plus fuel economy, because gear oils can add or detract from fuel economy to the tune of 1-2%.
Unless you know diff oil temps, you really can't make an educated choice outside of the OEM recommendations. You can evaluate conditions and operating environment and make a good guess, though.
In either axle, if you run light loads and seldom run heavy, gear oil temps will be low and a 75W90 will be fine. It will boost your MPG a little vs a 75W140. This will be especially true if you are a short hopper in town.
If you run heavy and/or spend a lot of time on the road and get the gear oil hot (hot being defined as at, near or over the 212F temp point used for measuring the viscosity grade), then a 110 or 140 could be in order.
Since I have used diff oil temp gauges for nearly a decade in my trucks, and in communicating with other drivers with trucks so equipped, I have some perspective on gear oil temps. Lightly used, most trucks will seldom see over 180F. If that's "it" for your truck, then running a 75W140 will result in a lot of wasted energy, because at that temp, the oil is very thick... in or near the 250 grade. And it stays that way forcing your truck to use extra fuel
If you haul or tow, especially over long distances, then you might see oil temps at 212F or higher. That's when the 140 grade comes into play.
My goal is to have the oil run at a viscosity equivalent to no less than the minimum cSt in the 90 grade, at the maximum temp the oil runs in my truck for any length of time. For my trucks, even though they tow regularly, it's for relatively short distances (field to grain elevator) and my diff temps seldom reach or exceed 200F. In that realm, 75W90 works great for me. Plus, I have a finned, high capacity cover that reduces my diff oil temps... plus the gauge is there to warn me if I get carried away.
Viscosity isn't the only protection in gear oil, don't forget. There is a bigger need for boundary lubrication in gear oil and that's why they are chock full of so many anti-wear additives. These additives provide much of the protection in gear oil and that's why it's not such a big deal to run shorter spurts at higher temps. It's those long, long runs at high temps that kill the gear oil and ultimately your rear axle.They are experimenting now with 75 and 80 grade gear oils and finding that with the right additives, they protect very well. Get on the Lubrizol website and find out more.
My overall logic is that if you tow or run heavy 5-10 percent of the time, it makes no sense to hurt yourself MPG-wise the rest of the time by running a heavier grade oil than you need.... even if that hurt is only 1-2%. If you lived in a cold climate that hit could be even more in the winter. If the oil temp exceed 212F towing for five minutes going up a hill, no biggie. It will cool back down. It's possible that you might see some overly high temps towing (which I define as over 250F) only occasionally, so you might have to take the hit in the daily driving department and use a heavier oil to preserve the axle. I contend, however, that a diff temp gauge allows you to monitor and make adjustments to the situation to keep that temp lower (see the list below). Also, a higher capacity, finned cover might be enough to maintain those lower maximum temps with a lighter oil, though it also keeps the oil cooler longer.
Assuming demonstrated overly high temps, I've crunched the numbers a couple of ways and using 1% drop of economy, it comes out somewhat cheaper to just use the heavier oil than to spend a lot of money on covers and such, but that would depend on how much hit there truly is on fuel economy and the cost of fuel. I strongly believe the diff temp gauge is a worthwhile addition for any truck that tows.
Some general things I have learned:
1) At a given load, a larger ring gear axle will run cooler than a smaller (more tooth contact to spread the load)
2) At a given load, a lower ratio (4.10. 4.56:1 etc) will run hotter than a lower (3.23-3.55:1, etc, ... more hypoid action creating more heat)
3) At the same viscosity a syn oil will run about 10 F cooler than a mineral, EXCEPT mineral oils with special additives. I used a LE oil (LE607), which was a straight 90 but one that had lots of a proprietary moly-like additive that surprised my by running as cool as a well-known syn. The Chevron ESI oils are said to exhibit similar characteristics, though I have not seen that demonstrated personally.
4) Fluid friction from an oil heavier than needed causes the oil to run hotter.
5) At any given load, the faster you go, the hotter the diff runs. Some of that is load due to windage but some comes from the diff itself... that hypoind sliding action occurring more often and heating the oil faster.
6) A higher viscosity oil than you need for the operating temp costs fuel economy.