Dually gearing? Coming from a SRW - Ford Powerstroke Diesel Forum
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post #1 of 15 Old 08-02-2019, 02:50 PM Thread Starter
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Dually gearing? Coming from a SRW

Sold my SRW, 3.73 with 285s on it (34s). Gearing felt great, at 2k RPM I was around 74 mph.

This new dually has 4.10s and 245s (like 31-32 inches). Aside from just being overall lower, the gearing seems super high, 2k RPM is 63 MPH. Feels like I'm in 4th all the time.


Question is, will my fuel mileage suffer cranking along above 2k RPM? I regularly go 70 or more in Utah and Nevada. I know I can go to 255s (33s) but I was thinking of regearing it myself. Worth it?

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post #2 of 15 Old 08-03-2019, 02:56 AM
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Keep the gears, get taller tires. It's not difficult to run 35's and get the RPMs where you want them.



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post #3 of 15 Old 08-03-2019, 06:00 AM Thread Starter
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Keep the gears, get taller tires. It's not difficult to run 35's and get the RPMs where you want them.

On a dually? For tires that big I'd need funky wheel spacers or different wheels. Gears are cheaper than wheels.
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post #4 of 15 Old 08-03-2019, 06:52 AM
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I was thinking of regearing it myself. Worth it?
Have you ever set up gears ? if so you know the drill dial indicators , in lb torque wrench , gear contact paste , experience over book is a key IMO

plus your pulling axles out to do this so you may be looking at more parts specially if 4x4

if not i would hand the job over to a shop and pay the extra for them to supply the gears so the whole deal is under their warranty


personally i like big tires ;-) good luck and keep us posted
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post #5 of 15 Old 08-03-2019, 07:09 AM
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To answer your question, Yes your mileage will suffer when you tach over 2000, that seems to be the magic number, at least on my truck. Temps will be different then what you're used too as well.

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post #6 of 15 Old 08-03-2019, 07:12 AM Thread Starter
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Have you ever set up gears ? if so you know the drill dial indicators , in lb torque wrench , gear contact paste , experience over book is a key IMO



plus your pulling axles out to do this so you may be looking at more parts specially if 4x4



if not i would hand the job over to a shop and pay the extra for them to supply the gears so the whole deal is under their warranty





personally i like big tires ;-) good luck and keep us posted
Yes, have set up lots of gears. No problem except for new parts. D80 gears aren't cheap, but cheaper than 6 wheels and 6 tires.

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post #7 of 15 Old 08-03-2019, 07:14 AM Thread Starter
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Originally Posted by SparkyF250 View Post
To answer your question, Yes your mileage will suffer when you tach over 2000, that seems to be the magic number, at least on my truck. Temps will be different then what you're used too as well.
Bummer. I like the power, but the cruise RPM feels all wonky. I'm betting I get used to it, but I don't want any worse mileage. A few MPG sure adds up on long trips.

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post #8 of 15 Old 08-03-2019, 07:29 AM
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Not sure what OEM gears cost, but here's good deal on some Yukon's. Pretty sure the Dana uses shims instead of a crush sleeve like the Sterling so it should be a little easier to set up.
https://www.amazon.com/Yukon-D80-373...omotive&sr=1-1

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2005 Explorer XLT 4x4 Mountaineer,
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post #9 of 15 Old 08-04-2019, 06:10 AM Thread Starter
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Originally Posted by SparkyF250 View Post
Not sure what OEM gears cost, but here's good deal on some Yukon's. Pretty sure the Dana uses shims instead of a crush sleeve like the Sterling so it should be a little easier to set up.
https://www.amazon.com/Yukon-D80-373...omotive&sr=1-1
Thanks. I'm both a Revolution and Yukon dealer. I also use a Crush sleeve eliminator kit when I use the Sterlings on a build (same one as most all Ford axles), but for the tow rig I would leave the crush sleeve. It's a lot faster for me actually.

Crush Sleeve For Model 20, Ford 10.25", 10.5", 7.5", 8.8", 9 3/8", 9"
https://www.yukongear.com/productdet...px?ProdID=8273
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post #10 of 15 Old 08-04-2019, 07:00 AM
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once you have the crush sleeve set isn't it as simple as removing it and replacing with a properly sized eliminator and thereby avoiding future issues ?

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