My current set-up is; 4.0L I-6, 5 speed manual, d35- 3.07 rear, d30- 3.07 front, 31″ tires. Currently, I cannot use my 5th gear on the highway, so I would like to re-gear to 4.10 or 4.53. I can’t decide if I should go with 4.10 or 4.53. The max tire size I would have is 33″, and I would like to maintain my current 15 city mpg. Which ratio would be best?
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I went here to get it regeared
To maintain best gas mileage/performance for your tire choice I wouldnt go larger then 4.10… If you plan to do 35′s then 4.53 would be a good investment, If it was me I just wouldnt feel comfortable putting those large of gears(4.53) or higher in a dana 30 or 35 (especially if its not a HP D30) the reason for that is the pinion gears tend to get smaller and smaller the bigger your gear ratios get, and for the D35 and D30 its already small enough, you will save yourself from shredding pinion gears every 6 months… Thats an easy choice with your tire size and axles 4.10 is the way to go…. Happy jeepin!
4.10 and make sure you do both front and rear diffs if you don’t you will tear up the transfer case and drivelines
I have an 06 Rubicon with 4:11 Dana 44′s and 33″ tires. But I have the 6 speed transmission. These gears seem to work very well with mediocore gas mileage, good towing capacity and highway rpm’s. I think with your 5 speed transmission it would work well also. My highway rpm’s with this set up is 38500 rpm’s at 70 mph. Your rpm’s with these gears might be a little higher with the 5 speed. I definiely would go with the 4:10 gears unless you’re going with bigger than 33″ tires. It might even be cheaper to just swap out your axles with Dana 44′s from a wrecked jeep, plus you’ll have more heavy duty axles, and could put on lockers later on if you’d like.