Alright, let me say first I am faily new to all this and hope I don't ask a question that's been asked a hundred times or a stupid one but I am hoping for a little advice on gearing. 

I am running a Sammi with a body and shackle lift with 32's.  I know, I know, I didn't put the lift on it, one day I will go to a SPOA but today is not that day. 

I have two sets of yukon 4.57 gears that I picked up to help out with the tires but the more I read, the more I read about T-Case gears and it seems like they do the job just as well with a little less headache. 

Am I wasting time with the axle gears?  How hard is this to do?  Do you have to completely remove the axles or just the 3rd member?  With the T-Case, I could install the new gears and just pop it back in but I already have the axle gears.  I was looking at the rebuild kit on low range for the axle gear swap/rebuild.  Is there anything else I am going to need? 

Any advice would be great. 

Thanks

Well the thing is it really depends on what you want to do.  First yes you can just remove the third and install the gears, its not that hard to do just take your time.  Same with the T-case.

Axle gearing will give you the same % of reduction in high (2wheel) as it does in low (4wheeldrive)  So for example stock samurais come with 3.73's in the axles.  I replaced mine with 4.62's and it gave me about a 20% reduction in high, and low.  This brought by my highway driving and 5th gear with 31x10.5 tires on.  It also gave me a 20% reduction for offroad in 4 low and 4 high.

Now T-case gears some times give you a small percentage in reduction for high but a big one in low as they are in the t-case.  For example some give you like 10% reduction in 2 wheel drive while when in 4 wheel drive 85% and higher..

Alot of people combine axle gearing with T-case but then you really cant drive highway speeds anymore. So its basically up to what you want to do...

t-case gears, hands down.

locjaw, t-case gears because they are easier to install?  do more for you with the extra gearing reduction in 4 wheel?  You have had experience with both and just prefer t-case?

I still plan on driving this on the highway occasionally, not interstate speeds, more like 55 or 60. 

Is getting the gears aligning properly, using shims and such, easier with a t-case or is it about the same?

I would go for t-case first. And in case it won't be enough then put those gears.... and 35" tires also )

Actually, you don't use shims with the Sammy.  You have adjustable sides that you can use to get everything in position, nice and easy.  With the T-Case it all just bolts in place, depending on your gear set you just have to do some grinding on the inside of the t-case to clear the gears.

The Transfer case, for ease of install, is a simpler way to run larger tires.  If you do a search you will see arguments one way or another.  Whatever has your lower gears is where the strain on your drive train starts.  So if you put lower gears in your differential, then the strain of larger tires is on the diff and axles.  If you put lower gears in the transfer case, the strain is on your t-case, diffs and axles.  This means you need to strengthen your mounting brakets and put better t-case mounts in and make sure all your mounting bolts have lock tight on them and are on tight or you will bend/rip parts off.

With the 4.62 gears and a 4:1 transfer case you will be a little low geared, but still able to do 60 without a problem.  It will just be wrapped up a bit more then usual.  But that is where your power is anyway.

Just for reference, I run 5.12 gears and a 6.5:1 transfer case.  But I only have the 4 speed and 1.0L engine.  But I can get up to 50+ with the 33x12.5 tires. 

With 32" tires, I'd go for the T-case gears. With 33"+ it's time to start considering making up the difference with diff gears so there isn't too much strain on the t-case & u-joints.

Thanks for the input guys, sounds like I need to start looking for some T-Case gears, anybody have some they don't need anymore    I really like the easier install and the increase in gearing in 4 wheel with the T-case gears...wish I would have done some more research before I got the diff gears. 

Joking aside, where would you guys recommend picking them up, I know there are a number of suppliers out there?

I might be selling these Diff gears to raise some money for the T-Case gears so let me know if anyone is intersted. 

Thanks for the input guys, sounds like I need to start looking for some T-Case gears, anybody have some they don't need anymore    I really like the easier install and the increase in gearing in 4 wheel with the T-case gears...wish I would have done some more research before I got the diff gears. 

Joking aside, where would you guys recommend picking them up, I know there are a number of suppliers out there?

I might be selling these Diff gears to raise some money for the T-Case gears so let me know if anyone is intersted. 

lowrangeoffroad.com

I have two sets of yukon 4.57 gears that I picked up to help out with the tires but the more I read

Sorry to say I completely missed this the first time 

I'm too lazy to do the math, but if those are the right diff gears to re-gear you to stockish, and assuming you don't have money lying around to burn, just put them in. It's not that hard, and you've already got them. Save your $$$ for a spool or lockrite to put in there at the same time. No sense in trying to sell what you've got to get something else that basically does the same thing.

Thanks for the link, looks like a pretty comprehensive article.  I am in an 87 Sami so I guess i can include that in the gearing factor. 

It seems like I will accomplish what I want with the 4.57's, should get me about back to normal and give me 5th gear back and also help out in 4 wheel drive. 

I want to be able to drive on the road as well and keep up.  So I want to find the solution that gives me some more power in 5th gear but doesn't limit my top end too much.  Looks like if I were to start over again I would go with T-Case gears, maybe 4.9:1, looks like those would work.  I already have the diff gears and don't really want to spend a lot more money so I guess I will try my hand at installing those. 

If I turn it into a pure "trail rig" one day maybe I will also go for some T-case gears

Diff gears are good for a "trail rig" too - they tend to keep the rest of the drivetrain alive longer.