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Diff gears are really only suitable for offsetting large tyres on road. They do nothing (significant) to improve off road capability unless they are so low you can't drive on road any more.
Here's the proof.
I've punched some numbers into my gearing calculator
Diff gears alone:
Stock sierra RPM@100: 3475 Stock sierra crawl ratio: 29.85:1 and speed at peak torque in low 1st: 14km/h
Stock sierra with 31's rpm@100: 2915 Stock sierra with 31's crawl ratio: 29.85:1 and speed at peak torque in low 1st: 17.41km/h
Sierra with 31's and 4.57 diffs, rpm @100: 3600 Sierra with 31's and 4.57 diffs, Crawl ratio: 36.86, speed at peak torque in low 1st: 14km/h
Sierra with 31's and 5.38 diffs, rpm @100: 4200 Sierra with 31's and 5.38 diffs, Crawl ratio: 43.4 speed at peak torque in low 1st: 12km/h
Yuk. with 4.57, you get back 5th gear on the highway, but you're stuck with the equivalent of stock gearing offroad. with 5.38, you're revving too hard on the highway and it's a little bit better than stock offroad. (but only a little bit)
Now, a sierra with 6.5's and stock diffs:
Sierra with 31's and 6.5 transfer, rpm @100: 3413 Sierra with 31's and 4.57 diffs, Crawl ratio: 87.78 speed at peak torque in low 1st: 6km/h
That's more like it. Road drivability is almost the same as standard, but off road you have a proper low range.
There's no reason to go into the diffs until you are going really big with tyres. The problem is, you'll always need to gear the transfer, and as transfer gears drop high range as well, if you go to, say, 33's, you're still spinning pretty hard on the highway once you combine, say, 4.6 diff gears and a 6.5 transfer.
There have been/are advocates of using 5.12 vitara diff gears and the 1.0 transfer case, which means you can buy wrecker gears and an off-the-shelf transfer. For th sake of the exercise, I'll put those numbers in here too.
Sierra with 31's, 5.12 diffs and 1.0 transfer, rpm @100: 4437 Sierra with 31's, 5.12 diffs and 1.0 transfer, Crawl ratio: 47.65 speed at peak torque in low 1st: 11km/h
Sierra with 33's, 5.12 diffs and 1.0 transfer, rpm @100: 4168 Sierra with 33's, 5.12 diffs and 1.0 transfer, Crawl ratio: 47.65 speed at peak torque in low 1st: 11.6 km/h
I reckon that's a terrible outcome. It might be reliable because it's all stock parts and the load is shared, but in my opinion, that gearing is only good for mud once you are offroad and sucks on the highway.
Just some thoughts.
Steve
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