Did the cross-Canada drive this summer. Went the northern route on the way out east, and the U.S. route on the way back.
The U.S. route is A LOT safer. Divided interstate all the way, 24 hour gas and food superstations every couple hundred miles or so. I 90 is definitely the way to go. Just make sure you avoid Chicago at rush hour! That will tack on 2-3 hours of stop-and-go right there.
I've heard the Northern route is brutal during the day time. You get caught behind a convoy of semis and there's not a lot of places to pass. I drove it during the night so I was able to just fly. Only problem was the giant MOOSE signs positioned every 5 km. You've basically got bush on either side of the road and curves aplenty, so I was convinced I was going to get a moose through my windshield around every bend. Ended up not seeing even one, but I've heard of other people who weren't so lucky.
402 ---> Sarnia border crossing ---> I 69 ---> I 94 ---> I 294 (Chicago toll highway) ---> I 90
then it's your choice. I 90 all the way to Montana and up the I 15 to Calgary, or I 94 up to Fargo, and then the I 29 up to Winnipeg and back to Calgary via the trans.
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