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I've got an '04 Ford F150, 4x4, Supercrew, 5.4ltr. engine. Happy with the truck but it has 3.55 rear end gears, definately not suitable for towing.
I'm pulling a 27' travel trailer (with 8' slideout), about 6,000lbs. When loaded, I'm about at my max. of 7,200lbs. I'm really feeling the truck struggle. It isn't unusual to be floorboarded running 25mph up a hill. I'm just waiting to smoke the transmission; and yes, I'm using my gears in the hills. Flat, level surfaces are no problem. But who wants to go camping all the time in flat level terrain? I added a Superchips programmer which did help only slightly. Towing in hills/mountains is painful.
I'm looking to move to 3.92 or so for the rear end. However, being a 4x4, I understand I would have to regear the front as well.
I'm looking for responses from someone that is knowledgeable about this process and/or someone who has actually regeared a 4x4 as I don't have a clue where to start. Again, I'm happy with the truck (95% of my time is non-towing) and am not in a position to replace it anytime soon.
I'm not doing any better with the 4.10's in my '05 4x4 HD Scab 8' box. I get about 12 around town and 15 on the highway with winter fuel. It pulls as well as my old F250 with 3.73's. At 2000 rpm I do about 67 mph in overdrive.
The 3.73's may be the best of both worlds. If I had a choice that's what I would have preferred.
I like 4.56 gears for towing, but 4.10 are more reasonable
I tow a 9000 pound trailer over 6% grade regularly and if you regularly tow, go with 4.56. If you only tow sometimes go with 4.10s. But my gas milage dropped to 14mpg. Mine is 4x4 and it cost me around $1200 to do front and rear. I love 4.56 gears, the truck does really well, even when towing it's max capacity just takes off from dead stop with no lag. Also FYI your speedometer will be off and when I asked my local dealer they couldn't recalebrate it so I had to buy a programmer to do that.
We're talking about 5% of the time towing, and 95% as a DD, which IMO, hardly warrants anything lower than 4.10's.
Even with that said, a gear swap is hard to justify the $1500 outlay, IMHO.
I'd look for a set of shorter tires before pouring $1500 into the truck for gears that would be lucky to see a 14mpg average.
What size tires are you running rcknrbn? Might be tough to go the shorter tire route on these '04+ F150's....I don't know if a 16'' rim will clear the calipers on these trucks.
Re-gearing is something that should only be done by someone that has done it several times.
Too much or too little in the measurements will eat up a set of gears in a hurry.
Anybody that specializes in driveline componets is usually the best bet.
Also, check into supplying your own parts, alot of times you can get great deals on quality gears and componets via places like Randys Ring and pinion, Drivetrain specialists, and other internet sources including Ebay.
Depending on the miles on your truck the minimum would be gears, pinions, pinion bearings and races, crush washers, pinion spacers, carrier shims, and pinion seals.
Make sure that you save what ever parts they pull out, as they could be Ebay'ed as a whole lot.
I'll just addd that you need to do some serious shopping as far as who installs the new gears. If that ring and pinion isn't shimed exactly to the right "timing" you'll tear those gears up within 20K miles (probalby just in time to be out of the shop's warranty...).
Shop around for a shop that does a LOT of gear changes like this. Have a chat with the mechanic himself that does that work to see if, well, to see if he's an idiot.
Take your time and choose a place that you're comfortable with.
I also agree that the 4.10 would be the best shoice.
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