Originally Posted by lokdzuk
i'm looking into a set of reduction gears and was wondering what every one else thinks of them and what are all the pro's and con's i already know the give you excellent rock climbing ability's
Everyone? Now that's a TALL order! Transfer-case gearsets are possibly the most popular discussion subject. For the Samurai, they are identified (named) by their low-range ratio, most commonly:
4.16:1, 4.89:1, 5.13:1, 6.5:1 and even 8:1, all with some high-range reduction as well, roughly 12-24%, depending on gearset.
T-case re-gearing is best regarded part of an overall
gearing change to adapt to larger tires and your intended application. Low range in the OEM Samurai gearset is 2.268:1, but many folks want more pulling/climbing wheel torque, especially after installing larger tires. Using my rig as an example, I'm on 29" tires (+10% diameter) with a 4:16 T-case with 12% additional high-range reduction (closely matching my larger tires). For me, it's important to preserve 5th (OD) gearing for the highway. My application is (way too much) California freeway driving and desert 4WD trails with no real rock climbing. Your needs will be different.
Edit: Lower T-case gears add stress on the mounting arms from the reaction torque. The many solutions to frequent T-case mount bending and breakage indicate the magnitude of this issue. If you need a lot of reduction, it's generally considered best to change the Ring & Pinion gears as well, and not perform ALL the gear reduction in the T-case. With modest changes, say 4:1 T-case gears and a gentler driving style, you might do well enough with simple mounting arm strengthening, as offered by Petroworks (-- that was my choice).