I have a 75 cruiser with a 350 chev, stock 4-speed tranny and t-case. I just picked up a set ob 38.5 boggers, and like to crawl. I was running 4.11's and 35's, liked it, but would like to go a little lower. My concern is I have been told the pinion gear is tiny and prone to breakage. Whats you thoughts?
Size of the pinion is really not an issue, compared to the amount of ring gear tooth that needs to be removed in order to get the spider gear pinion shaft removed from the carrier in a semi-float rear axle application.
If you are going to install them into a full-float axle assembly, I would not worry about it.
I have installed them into a 40 series running 38.5SX Swampers with a full-float rear axle assembly and they work fine
I have been running 5.29's in my 40 for the past 6 years. I run a full float in the rear w/ a Detroit. ARB in front with 37" IROKS and an Orion. Tellico was (????) my main trail system. I have run all the trails without a single problem. I think any thoughts on weakness are overly pessimistic. My 40 is not a trailer queen. It will do about 62-65 on the highway (a hazard in Atlanta traffic) But I get by and I really like the crawl.
I am running the 5.29's with 35/13.50's. 4 speed tranny and a sbc. lockers front and back, with a rear floater. I love the crawl ratio. And like Mudnyreye I too can cruiser the highway at 65. rpm's are about 3200. They are great...
I'm running 38.5's with 5.29 Yukon gears. No issues. The tooth grind to get the center pin in isn't an issue. It takes very little material off and should not materially effect strength. I've never seen an fj40 pinion fail at the teeth. I can't say that it hasn't happened but everyone I've seen fail had done so mid shaft near the flange. Usually from axle wrap. I have no fear over pinion strength. 5.29 seems about right for 38's. And no with stock tranny/transfer case the crawl ratio is not great. It's about the same as stock gearing and stock tires.