After the usual fiasco, I'm regeared to 4.56-
Placed an order almost two months ago with East Coast Gear Supply. After a month of not seeing anything on my door, and not being in a rush, I called them- and for some reason nothing had shipped yet. They got it out immediately, sent me a tracking number, and I made an appointment for two weeks in advance to have the gear and axle shop here install the gears the same day I drop the diffs off.
Spent the day before the appointment pulling the differentials, and drop them off early the next morning. Everything went smooth for the rear, but I got a phone call saying I provided the wrong gears and bearings for the front. Turns out ECGS sent the correct Nitro gears and master install kit for the rear, but they sent me the front gears and master install kit for an 05+ Tacoma, although they had my truck correct on file. Clearly their mistake, and they couldn't offer anything else other than having me pay for another set of gears and another install kit and waiting for it to show up. I chose not to do that and sent back the incorrect parts on their dime.
I borrowed my roommates 1984 4wd Tercel wagon we've been working on and drove almost 100 miles with no A/C and a drivers door that would not open to pick up the correct master install kit from Low-Range Offroad. All said and done I am running Sierra gears in the front diff, Nitro in the rear, and Nitro's master install kits in both the front and rear. Glad that's over with.
It seems that every company suggests a slightly different way to break your gears in, but I called and chatted with Nitro on the phone and went with what they suggested. 85-140w dino oil in the diffs. Synthetic is too slippery. 8-10 minutes of driving 40-45 mph and then allowing a cooling cycle for 30 minutes. 4-5 rounds of that, and then 500 miles of no towing or rock crawling or "off-road racing", following by changing the gear oil and filling it up with whatever I like to use. Essentially the gears hardface themself during that initial break-in, and and improper break-in leads to chipped teeth and a voided warranty.
After the initial break-in, I packed up the truck with camp gear and drove 200 miles round trip- from my house at 4700 feet up to 11000 feet. I'm familiar with all these grades and am so damn happy with how the truck drives now! My transmission shift points are much better, I can pull grades without downshifting, and just saw a huge improvement of MPG on this trip. I'm still taking it easy and avoiding hard downshifts, but my truck has balls once again- this time with 35s.
On the way to the camp spot-
Had to turn around and do it again!
Now I need to make a note about my MPG. I drove to Southern CA and back a month and a half ago, with 35s and 3.91s, and got between 13.8 and 14.2 MPG. Terrible. Not to mention the truck couldn't pull a grade without downshifting or anything like that. My mileage was within this 13.8-14.2 range the entire time my truck had 35s/3.91s. After I did the cowl induction snorkel, I filled the tank, reset the odometer and my scan gauge as always, and drove as I normally do to where I normally go. 15.4! Seems too good to be true, and I can't rely on a single tank to provide an average MPG, but I'll hope for the best.
On this weekends 200 mile trip, through the mountains with an easy 20 miles in 4wd, probably at least 2 in 4lo........ I just got 18.4 MPG. I can hardly contain my excitement. And the power is night and day better than it was before! Plus 4lo is so LOW! I usually get better mileage driving to work and back than on a trip through the mountains, but I check my mileage every tank and will post back. I haven't seen a number anywhere close to that since I had a camper shell, 33s, and drove 65 for 350 miles.
Super hyped on the gear change.