Dana 60/Dana 80 Gear Advice

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Sep 24, 2010
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Location
Soldotna, Alaska
Website
www.grizzlyoffroad.com
I have a customer that I'm building a 94 Dodge for. He has a Dana 60 in the front and a Dana 80 in the rear. I'm having a problem deciding on the gear ratio we should go with and need some real world advice. Basically, our options are to run 4.30 in both, mix and match with 4.56 front and 4.63 rear, or 4.88 in both. He is going to run 38" tires with auto tranny, so what do you think the best set will be?? The truck will be mostly for wheeling and maybe some towing, not really a daily driver, but still want's a all-a-round truck...not just mud drags. Has anyone out there ran the 4.56/4.63 combo?....any problems? Let's here your opinions guys. Thanks for the help!
 
I think his best option is to ditch the Dodge, and go Toyota!

I kid, I kid!

Just pointing out that a "mix and match" solution where one gearset and the other don't entirely match may led to t-case failure, if not at least driveline binding... otherwise, with 38" tires, though, he's gonna need steeper gears than anything in the 4 ratio, 5.29's or 5.38's for ideal power, though the 4.88's would be about middle of the road.

4Lo.com :: Gear Ratio & Tire Size Chart
 
Thanks Chuck...

Yes, I was questionable about mixing ratios, but the Gear manufacture is the one that actually suggested it! He said that was the most they liked to differ, but lots of people do it.

I agree, I think the 4.88's would be fine. The customer thinks they will be too low, but I know he will like it....better too low than too high!
 
Thanks Chuck...

Yes, I was questionable about mixing ratios, but the Gear manufacture is the one that actually suggested it! He said that was the most they liked to differ, but lots of people do it.

I agree, I think the 4.88's would be fine. The customer thinks they will be too low, but I know he will like it....better too low than too high!

Is this dodge a diesel or gasser?

The difference you speak of in gearing is less than having unevenly worn tires. That is why the gear vendor suggested it. Its so close its fine.

Some rigs came stock with 4.09 and 4.11 gears for example. Sometimes you got to work with what available.

I have built several rigs with 5.29s and 5.38s when mixing dana spicer and import axles together.
 
I think his best option is to ditch the Dodge, and go Toyota!

I kid, I kid!

Just pointing out that a "mix and match" solution where one gearset and the other don't entirely match may led to t-case failure, if not at least driveline binding... otherwise, with 38" tires, though, he's gonna need steeper gears than anything in the 4 ratio, 5.29's or 5.38's for ideal power, though the 4.88's would be about middle of the road.

4Lo.com :: Gear Ratio & Tire Size Chart

Is this dodge a diesel or gasser?

The difference you speak of in gearing is less than having unevenly worn tires. That is why the gear vendor suggested it. Its so close its fine.

Some rigs came stock with 4.09 and 4.11 gears for example. Sometimes you got to work with what available.

I have built several rigs with 5.29s and 5.38s when mixing dana spicer and import axles together.

Really need to know if gas or diesel for proper gear choice. If a diesel I would NOT go lower than the 4.88's. my dodge diesel if stock gearing on 35's and it is hadley nocicable from the 33's I am 4wd and have factory 4.11 front and rear in my D60 and D80 hybrid axles. I would probably recommend the 4.56 / 4.63 combo if a diesel and if the gear vendor suggested it im sure it will be fine. it isnt a drastic change. and like stated above its like having some unevenly worn tires. if worried about binding dont go into 4 wheel unless off of paved road. :meh:
 
It's a gas engine that he plans on building strong and pumping out some pretty high horsepower numbers. We haven't gotten that far in the build, but this truck is going to be a romper and will need good power! Thanks guys, keep the comments coming!
 
4.88's definitely. I don't know what the stock ratio was in that truck, but with 38's, I'm guessing he'll still be turning less rpm than when it was stock.
 
Well, I've posted this on a few forums....and it seems that the consensus is to go with the 4.88's. This was exactly what I would have done, but I didn't want to be solely reponsible for the choice if the customer wasn't happy:) Thanks again guys for all your help!
 
Kinda late to the party here, but yes gas engine 4.88's or a tad lower would be my choice since you dont have the torque of the diesel and you have a higher RPM redline than the 3000 the diesel has.
 
Actually if he thing in the towing option maybe deeper than 4.88 would be great .. and sure that will help the auto tranny building heat while towing
 

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