4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

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4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by California_RAM » Sat Apr 08, 2017 7:24 pm

I have seen several threads that discuss axle ratio, but they seem to get convoluted quickly. I have done the math, and I need to be at 4.56 axle ratio for my towing application of a 8,800lb camping trailer (pictured below). The OEM 4.10 is too high, and my transmission goes over 200 degrees during heavy use. I have a real straightforward question. Does anybody have a good experience upgrading to 4.56 in a newer generation Power Wagon (2015 in my case)? Is anybody familiar with a good brand to go with for a 4.56 R&P kit? I am currently talking it through with a local 4 wheel parts, and their G2 axles representative. They can do it, but it feels like a lot of discussion on spacers and shims, and even a GM gear set instead of a Chrysler. In other words a total custom set-up. I am looking for near stock dependability and reliability. I want to avoid the loud noises, and reliability horror stories that I've read about. But, I cant find a manufacturer with a clean packaged set-up that gets you to a 4.56 axle ratio. Also I added some recent Moab pictures to soften the blow of all the nerd talk. Thank you for your feedback.
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AEV Lift kit handles significantly better then stock. But, the 4.10 axle ratio is too high for 37" tires.
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by DamageWagon » Sat Apr 08, 2017 7:45 pm

That's ridiculous. It's the same axle as has been used in all the diesels since 2003 or 2004 if I remember right. Those gear sets are a dime a dozen. Heck I think almost every guy at the DTX get together a few weeks ago had 4.56's or 4.88's in their 11.5's. Unless I'm wrong about the axle, and I'm almost positive it's the same, the guys at 4WP have no clue what they're talking about, as usual. G2 should make a set that drops in.


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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by DamageWagon » Sat Apr 08, 2017 7:48 pm

Now that I think of it, they may be confused and think you have a 10.5 axle like I do. That one is hard to find gears for. It has some crossover with a GM 14 Bolt. The newer 11.5 like you have has options everywhere.


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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by usmc369 » Sat Apr 08, 2017 8:04 pm

Waste of time and money for such a small change.
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by California_RAM » Sat Apr 08, 2017 8:23 pm

USMC369: How was your experience on adding 4.88 R&P? Who did you go through, and do you have a 6.4L as well?
2015 RAM Tradesman PW: White Knuckle Sliders, FAB FOURS premium bumpers front and rear, Magnaflow #19200 exhaust. K&N cold air intake.
Suspension: AEV 3" lift w/ OEM 2500 springs.
Tires: 37x12.5R17 Toyo Open Country R/T, mounted on AEV 8.5" wide Katla wheels. Corrected Ring and Pinion gears: 4.88 Yukon (front), and 4.88 AAM (rear). AEV differential covers (front + rear). Thuren XHD swaybar endlinks.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by TwinStick » Sat Apr 08, 2017 8:43 pm

California_RAM wrote:USMC369: How was your experience on adding 4.88 R&P? Who did you go through, and do you have a 6.4L as well?
IIRC, he loved it.

I would go lower (numerically higher) than the 4.56's in my 3rd gen if i could. Would require a 11.5" axle housing though. Then I could go to 5.13"s, run larger tires & still be able to use it for HD work.The axle shafts in my 10.5" are the same part # as the diesels rear axle shafts. Many people blow smoke & say you don't need them, I suspect they are the ones that don't use their HD truck like a HD truck. Those that do realize quickly, that lower gears (higher numerically) would really help them out. Especially if you lift it, put bigger tires on it & still want to do HD work with it. Yes, the mpg sucks, no doubt, but it is hard to get both with a gas engine. My truck is a perfect example. Pull its rated max load with authority---compared to the same 345hp Hemi w/545RFE auto trans w/4.10's, of the 04 2500 we had. Gets horrible mpgs but I'm still lovin it. They could certainly fix the problem with a small diesel w/about 450-500 lb ft of torque & bring back the G56 option, but we certainly would not be able to afford one. I also think many are at the point of saying F*** the Power Wagon because they need the torque of the diesel for their HD work & just getting some ARB air lockers & maybe a winch for some trail action. Because I said F*** my employer & retired (& my wife too) we will only be able to buy one vehicle at a time now & have to keep them for a good long time as well.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by 04Ram2500Hemi » Sun Apr 09, 2017 12:30 am

Take a look at the following build thread. At page 8 he documents going to 4.88 gears.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by usmc369 » Sun Apr 09, 2017 9:17 am

I was the 1st to do the change on here in the newer generation trucks so I was a guinea pig. They used yukon gears front and rear and initially all was well, then it started sounding like a helicopter. I went back to the installer and they agreed to change it too AAM 4.88 r&p in the rear. It has been smooth sailing ever since with no noise. Rpms are higher but i have stock exhaust so their is no noticable noise difference. I was told their is no carrier break on 11.5 chrysler axle so a shim wasnt required. Im vey happy with mod so far, and just changed the gear oil and everything looked good. I have about 20,000 on the new gears. If you have 33" tires you have to keep your foot on the brake because it will walk on you at idle, even up a hill. :shock:
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by OffroadTreks » Sun Apr 09, 2017 11:16 am

Why go so steep with gears? There is a guy on AAV with a Ram 2500 diesel on 37's who went with 4:30's. 1500 RPM at 60 MPH &1800 RPM at 70 MPH. Just wondering if anyone is considering RPM speeds, especially when towing or under load when talking about gears. Driving around at 2500 RPM while towing is going to get old fast.

But I'm curious because towing performance is the one thing holding me back from 37's right now. And I've been wondering what would be the best gear combo for towing.
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4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by DamageWagon » Sun Apr 09, 2017 12:01 pm

The go-fast diesel guys are running 4.56 and 4.88's for more get-up. I wish my truck had the torque of you 6.4 guys. If I have no load I can cruise down the freeway at 1500rpm and get awesome mileage, but any load and I either have to drive faster to get into the power or downshift. 2000-2200rpm is my freeway speed at 60-65mph. If I had 4.88's the RPM's would be higher but these engines need RPM's to make power. The 6.4 is better, but if you have towing issues then going deeper in the gears would be a good idea. I wouldn't want over 2500rpm for normal driving, but is that really that bad?


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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by TwinStick » Sun Apr 09, 2017 12:20 pm

Going deep with gears (either in the transmission or the axles or both) is the only way to get gas engines to do HD work. That is proven with most older vehicles and old Power Wagons. They were geared low, like a tractor, to do work/farm work. Many older 4wd's had a top speed of about 45 mph. Our landlord when i was a small child, had an old 1950/60 Chevrolet, with a 4 speed. He used to use it to disc the fields when the tractor wouldn't start. Lo range 1st gear all day long. I used to ride with him sometimes, even though his tobacco chewing/spitting was gross beyond belief. :lol: I have no doubt that i could do that with my truck as well @ 78:1.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by nts007 » Sun Apr 09, 2017 12:31 pm

MikeKey wrote:Why go so steep with gears? There is a guy on AAV with a Ram 2500 diesel on 37's who went with 4:30's. 1500 RPM at 60 MPH &1800 RPM at 70 MPH. Just wondering if anyone is considering RPM speeds, especially when towing or under load when talking about gears. Driving around at 2500 RPM while towing is going to get old fast.

But I'm curious because towing performance is the one thing holding me back from 37's right now. And I've been wondering what would be the best gear combo for towing.
The cummins is designed to be most efficient between 1900-2300rpm. 1500rpm in 6th is lugging. I have a gauge that reads instant fuel consumption as mm3. Running in 6th at 1900 rpm takes 30% more fuel than 2200-2300 in 5th for the same speed while towing.

Just because they are doing it means nothing. Also think of the intelligence level of the people purchasing a $70k truck and immediately dropping another $30k+ to make a tow rig. Oh right I forgot AEV knows best :lol:

The best way to gauge and calculate what you need for gears is to match up your larger tires with a gear ratio that keeps the rpm and the transmission at stock output levels. So if you are 2000rpm at 70mph with 31's then you need to be 2000rpm on 37's. That is the correct way to gauge your final drive. Guys who run 3.73s on 37's (like most diesel guys) and tow are a dealership or diesel shops best friend!! ;) that level of intelligence keeps the industry alive
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by ramv » Sun Apr 09, 2017 2:05 pm

MikeKey wrote:Why go so steep with gears? There is a guy on AAV with a Ram 2500 diesel on 37's who went with 4:30's. 1500 RPM at 60 MPH &1800 RPM at 70 MPH. Just wondering if anyone is considering RPM speeds, especially when towing or under load when talking about gears. Driving around at 2500 RPM while towing is going to get old fast.

But I'm curious because towing performance is the one thing holding me back from 37's right now. And I've been wondering what would be the best gear combo for towing.
So my last truck had an 8.1, 4.10 gears, 30" tires and only a 0.75 OD from the factory. Cruised at 85 to 90 no problem. (2800-3000 rpm) When I traded it, it had 200k miles and still ran like new. Towing 12-15k lb over mtn passes would see it run at redline for 30-45 minutes or more. Never got hot, transmission would get a little warm towing at lower speeds since it didn't have a lock up, but never above 210 deg F (which was the engine's working temp and where the aux fan kicked on.) It was the original transmission, nothing special other than synthetic fluid, changes every 50-75k miles.

My 2nd gen I had 5.13s and 37"s and a single OD, and drove it everywhere, all over the West, Midwest, Midcon. It was so much more responsive with 5.13s than with 4.10s and 35"s. As well the transmission got a lot hotter with 4.10s then 5.13s. (I was always chasing adding more aux coolers, fans, etc. The gears just solved problem.)

My point is, if you tow at all, I think you would rather have lower gears (4.88s, 5.13s for 35/37s) then worry about your on highway rpm. These things have double OD, and are speed limited to 99 mph, so cruising rpm isn't going to be an issue.

Now if I had a diesel, I would go for 4.10s with 35" and 4.30s with 37"s +/-. That's probably even a bit deep for a Cummins, not bad for a Dmax or PS as the V8s still rev better.

On the bid rigs I spec'd, I went ISXs (15 L inline 6 Cummins) with OD transmissions, and 3.90s. ( I was going to go 4.10s but the dealership talked me into 3.90s for mileage.) These are governed to 65 mph, and run at the meat of the power band (1000-1200 rpm) with 44" tires. (11R24.5). For optimal mileage, I would have gone 3.73s to get them into the lower edge of the power band, but considering these units always run loaded (grossing upto 105 k lb), I went for a few more rpm to reduce shifting and wear and tear on the transmissions over mileage.
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by OffroadTreks » Sun Apr 09, 2017 2:14 pm

That's interesting. We have no over-heating issues currently with temps. The 6.4 performs better in that regard than our 5.7 did. The 5.7 you knew it was working and when elevation and altitude was a factor, temps would climb.

Guess I'll have to compare 4:56 and 4.88's to see what would suit me best. Kings and 37's are in my future.
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by DamageWagon » Sun Apr 09, 2017 3:12 pm

MikeKey wrote: Kings and 37's are in my future.
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by TwinStick » Sun Apr 09, 2017 3:23 pm

The simplest solution (for the manufacturers) would be to design a computer program that will let the driver decide what gear to hold it in & for how long to hold it there. As we all know, the Hemi needs to rev to make its power. And to do away with the multiple overdrives. 5th gear should be 1.0:1 & 6th the overdrive. They would just have to have a rev limiter, to avoid engine failure. My atv had this back in 2003 & it worked well. (when pulling the weight sled, 1st gear Lo range, take off slow, then hit the rev limiter & just back off a tiny bit & hold it there, in its best powerband. Yes lower gears will certainly help. But a simple trans computer program change would be a great start & lower gears with less gaps in between them would also go a long way.

I will be keeping a close eye on the towing performance of the new 10 speed Ford, their new small diesel and the 5.0L. All will be mated to the 10 speed auto. I just hope it does not end up being a 5 speed with 5 overdrives. :doh:

I also would not go with 4.56's. Go 4.88's. Don't fear the gear.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by nts007 » Sun Apr 09, 2017 3:37 pm

ramv wrote:
MikeKey wrote:Why go so steep with gears? There is a guy on AAV with a Ram 2500 diesel on 37's who went with 4:30's. 1500 RPM at 60 MPH &1800 RPM at 70 MPH. Just wondering if anyone is considering RPM speeds, especially when towing or under load when talking about gears. Driving around at 2500 RPM while towing is going to get old fast.

But I'm curious because towing performance is the one thing holding me back from 37's right now. And I've been wondering what would be the best gear combo for towing.
So my last truck had an 8.1, 4.10 gears, 30" tires and only a 0.75 OD from the factory. Cruised at 85 to 90 no problem. (2800-3000 rpm) When I traded it, it had 200k miles and still ran like new. Towing 12-15k lb over mtn passes would see it run at redline for 30-45 minutes or more. Never got hot, transmission would get a little warm towing at lower speeds since it didn't have a lock up, but never above 210 deg F (which was the engine's working temp and where the aux fan kicked on.) It was the original transmission, nothing special other than synthetic fluid, changes every 50-75k miles.

My 2nd gen I had 5.13s and 37"s and a single OD, and drove it everywhere, all over the West, Midwest, Midcon. It was so much more responsive with 5.13s than with 4.10s and 35"s. As well the transmission got a lot hotter with 4.10s then 5.13s. (I was always chasing adding more aux coolers, fans, etc. The gears just solved problem.)

My point is, if you tow at all, I think you would rather have lower gears (4.88s, 5.13s for 35/37s) then worry about your on highway rpm. These things have double OD, and are speed limited to 99 mph, so cruising rpm isn't going to be an issue.

Now if I had a diesel, I would go for 4.10s with 35" and 4.30s with 37"s +/-. That's probably even a bit deep for a Cummins, not bad for a Dmax or PS as the V8s still rev better.

On the bid rigs I spec'd, I went ISXs (15 L inline 6 Cummins) with OD transmissions, and 3.90s. ( I was going to go 4.10s but the dealership talked me into 3.90s for mileage.) These are governed to 65 mph, and run at the meat of the power band (1000-1200 rpm) with 44" tires. (11R24.5). For optimal mileage, I would have gone 3.73s to get them into the lower edge of the power band, but considering these units always run loaded (grossing upto 105 k lb), I went for a few more rpm to reduce shifting and wear and tear on the transmissions over mileage.
Your older trucks had it right. Proper gearing is a mechanical advantage. When the engine runs a bit higher rpm that's a good thing. More fan speed. More power available. More water pump moving fluid... It all makes less stress on the engine.

From experience, looking at my sig..... Running 4.56 with 37's has me 3-4% under drive compared to my originally stock 3.73 and 265/70-17s. My wife's dually on stock tires and gears is identical to my truck rpm highway speeds.

Now I did run 35's with 3.73s yes but mileage suffered even though I had more overdrive. The best mileage was on 285/70-17s (33's) with the 3.73s and now with more height and more tire I still retain very good mileage.

Revmax (transmission company) will not warranty their transmissions for trucks with larger than 35" tires unless you have proof of re-gearing to a more appropriate ratio.

Matching gears and tires will always keep stresses down through the the driveline. Just because you can doesn't mean you should. Hell I have more than enough power to make 42's work with 3.40 gears. But that's just plain dumb.

Transmission is always the biggest fail point when towing and oversized tires. If your pockets are deep then have at er. Love seeing guys with jacked up huge tire trucks pulling those huge trailers. Egt's theough the roof hahaha. Local diesel shop here has a few customers they love. Oil guys. Buys a new truck. Let's them 'do the works' and this guys hook up to a massive rv. Go show off and bring their truck back for transmission number 4......
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by DamageWagon » Sun Apr 09, 2017 3:40 pm

5.38's and be done with it. lol. Throw a Gear Vendors on behind your trans and you've got a 12 speed!


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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by olyelr » Sun Apr 09, 2017 4:06 pm

DamageWagon wrote:5.38's and be done with it. lol. Throw a Gear Vendors on behind your trans and you've got a 12 speed!


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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by Bill2014 » Sun Apr 09, 2017 4:48 pm

TwinStick wrote:The simplest solution (for the manufacturers) would be to design a computer program that will let the driver decide what gear to hold it in & for how long to hold it there. As we all know, the Hemi needs to rev to make its power. And to do away with the multiple overdrives. 5th gear should be 1.0:1 & 6th the overdrive. They would just have to have a rev limiter, to avoid engine failure. My atv had this back in 2003 & it worked well. (when pulling the weight sled, 1st gear Lo range, take off slow, then hit the rev limiter & just back off a tiny bit & hold it there, in its best powerband. Yes lower gears will certainly help. But a simple trans computer program change would be a great start & lower gears with less gaps in between them would also go a long way.
...
I still don't understand your beef with the 5th and 6th overdrives. Perhaps if you had experience with the 6.4 with the 66RFE you would understand why it makes sense. Towing at interstate speeds, the truck will stay in 6th on the level and shift down to 5th on the steeper inclines. When it's just the truck, it pretty much stays in 6th. There's nothing wrong with multiple overdrives even with the 4.10 gears.

When I had the '13 Powerwagon with the 5.7, it was a different story, it didn't do very well towing even with the 4.56 gears. So I got rid of it and got the '14 with the 6.4.

I don't know anyone with a Powerwagon that regularly tows as heavy as I do...
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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by Reloaderguy » Sun Apr 09, 2017 5:14 pm

Bill2014 wrote:
TwinStick wrote:The simplest solution (for the manufacturers) would be to design a computer program that will let the driver decide what gear to hold it in & for how long to hold it there. As we all know, the Hemi needs to rev to make its power. And to do away with the multiple overdrives. 5th gear should be 1.0:1 & 6th the overdrive. They would just have to have a rev limiter, to avoid engine failure. My atv had this back in 2003 & it worked well. (when pulling the weight sled, 1st gear Lo range, take off slow, then hit the rev limiter & just back off a tiny bit & hold it there, in its best powerband. Yes lower gears will certainly help. But a simple trans computer program change would be a great start & lower gears with less gaps in between them would also go a long way.
...
I still don't understand your beef with the 5th and 6th overdrives. Perhaps if you had experience with the 6.4 with the 66RFE you would understand why it makes sense. Towing at interstate speeds, the truck will stay in 6th on the level and shift down to 5th on the steeper inclines. When it's just the truck, it pretty much stays in 6th. There's nothing wrong with multiple overdrives even with the 4.10 gears.

When I had the '13 Powerwagon with the 5.7, it was a different story, it didn't do very well towing even with the 4.56 gears. So I got rid of it and got the '14 with the 6.4.

I don't know anyone with a Powerwagon that regularly tows as heavy as I do...
His truck has 150hp, it kind of influences his world view in an odd way.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by TwinStick » Sun Apr 09, 2017 5:34 pm

:idea: Yup, thats it. Your a genius.

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by TwinStick » Sun Apr 09, 2017 5:37 pm

F Forward 15 years & everyone will think they need a 1 ton dually with 1000hp to pull their 8800 lb trailer. :sick:

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by Reloaderguy » Sun Apr 09, 2017 5:46 pm

TwinStick wrote::idea: Yup, thats it. Your a genius.
You're

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Re: 4.10 to 4.56 axle ratio upgrade kit for 2015 PW?

Post by nts007 » Sun Apr 09, 2017 7:58 pm

TwinStick wrote:F Forward 15 years & everyone will think they need a 1 ton dually with 1000hp to pull their 8800 lb trailer. :sick:
So I shouldn't twin turbo the wife's truck??? :lol: :lol:
08 ctd--mini max--thuren 3" coils and LT Leaves--4.56 gears and lockers in pw axles--some lights--afe intake system--bd super b turbo--Banks w/m Injection--Dynatrac Balljoints--king 2.5"s--37" Hankook Dynapro MT--DOR Long arms--Custom emf track bar--Manual T-case swap--Full PW Under armor--PSC Hydro Assist and so much more

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