im going to be trading a kid near me a brand new clutch kit and a brand new flywheel for some 4:16 tcase gears he only used a couple months.

My question is when I install them and rebuild my tcase will a simple rebuild kit with bearings,seals, and gaskets be enough or is there more I need? Im new to this whole 4x4 world still and one buddy of mine says theres more I need. Lowrangeoffroad has a $79 kit, a $115 kit, and a $215 kit.

Also do you guys think that these would be good gears for me to go with on my rig? Right now I have an 87 samurai with a stock 1.3, harley myside kit, 3" deaver spring under, 31x10.50x15 tires, and 5.12 front sidekick diff in my samurai front axle and  a 5.12 rear sidekick diff in a hybrid housing. Im in college for the next couple years so this is my daily driver and mild wheeler.

You should check this out.
http://www.lepayne.com/gears.html

My question is when I install them and rebuild my tcase will a simple rebuild kit with bearings,seals, and gaskets be enough or is there more I need?

Your going to need the basic kit, seals and gaskets. Have you damaged your bearings inside the Tcase the gears are going in? Crack it open, take a look before you go crazy buying bearings in advance.  Ya may not need them.

Also do you guys think that these would be good gears for me to go with on my rig? Right now I have an 87 samurai with a stock 1.3, harley myside kit, 3" deaver spring under, 31x10.50x15 tires, and 5.12 front sidekick diff in my samurai front axle and  a 5.12 rear sidekick diff in a hybrid housing. I'm in college for the next couple years so this is my daily driver and mild wheeler.

For the gearing to tire size question.  I use this http://www.lepayne.com/gears.html to figure out what I wanted to do. The 4.16 gears along with the 5.12 R&P, HELLIFIKNOW!!     Bottom line of it all, what is your endstate? What do you want to do with the rig? Once you get that figured out start looking for parts you'll need.  

I just went down this road. Bought a Tcase w/gears. The guy was straight foreward and honest saying that the case had gotten water in it.  I bought it, broke it open and rebuilt it .

pretty sure I had water in it is why im looking at a rebuild kit. when I got it I changed the oil and it came out really bad smelling and was milky white.

thanks for the input guys. right now or atleast for the next couple years of school I plan to stay with 31's and then when thats done I will do yj spring over with 33's and I think thats as nig as I will go since this will be a daily driver for quite sometime.

I was running the same setup as you - 5.12 gears (hybrid rear) and stock t-case and 31" tires on my '87 Sami and it SUCKED off road and wasn't great on road, due to gearing. Lower t-case gears would have made it worse on road (higher rpm's) but will help a little bit off road.
I played with the gearing calculators and I did alot of looking around (to do it once and be done) and ended up going with Trail Tough 6.4 t-case gears and swapping to 4.30 R&P gears. The 6.4 gears offer a 181% low range reduction and only a 17% high range reduction. I wanted some really low crawling gears but still be able to drive on the freeway.
This setup also has my speedo back to being accurate again.

I would like to go to a 33" tire once the 31" tires wear out and this will drop 250 rpm's off at freeway speed but I will lose my accurate speedo again.

The setup you have now is good for :
65mph at 4069 rpm
crawl = 42:1

The 5.12 gears with 4:1 t-case :
65mph at 4554 rpm
crawl = 78:1

The 6.4 t-case with 4.30 R&P :
65mph at 3996 rpm
crawl = 100:1

http://www.grimmjeeper.com/gears.html

So to answer the question "do you guys think that these would be good gears for me to go with on my rig?"
I would say it depends on what your daily driving involves such as what speed you need to drive to not be a rolling road block.

For me I wanted to be able to run the freeway to work when needed and any t-case gears with the 5.12 R&P gears would have kept me from safely doing it.

saturday im picking up 2 early 70's fj40 axles, keeping the rear and selling the front to get a mini truck front axle both geared 4:10 with 33's in the future.

Bottom line - Make this project a marathon.  You will have more beer money during the project and time to consider each step of the project.  Build a map of the project so you can see each step and all necessary items of each step.  Just my .02

I totally agree. It took me awhile to learn this and cost a few dollars along the way.
Now I hold out on buying parts and save cash, then buy exactly what I want once and be done.
My project is nearing an end, not sure what else I can/would do..... almost time to start another one
My next one is going to be a straight off-road only project.

saturday im picking up 2 early 70's fj40 axles, keeping the rear and selling the front to get a mini truck front axle both geared 4:10 with 33's in the future.

Find out the exact year of the FJ 40 and Mini Truck axles.  I know some early 70's, front, FJ 40 axles are better thank the Mini Truck front axles.  I have a friend/mechanic/yota guru that wheels yotas (we are going this weekend).  He is like, well, Yoda when it comes to Yotas.

(bad joke. couldn't help myself     )

Quote from: airmanwilliams on March 24, 2011, 07:12:31 AM

saturday im picking up 2 early 70's fj40 axles, keeping the rear and selling the front to get a mini truck front axle both geared 4:10 with 33's in the future.

Find out the exact year of the FJ 40 and Mini Truck axles.  I know some early 70's, front, FJ 40 axles are better thank the Mini Truck front axles.  I have a friend/mechanic/yota guru that wheels yotas (we are going this weekend).  He is like, well, Yoda when it comes to Yotas.

(bad joke. couldn't help myself     )

late 70's and 80's are the best fj axles. and all are stronger than the pick-up axles but at a price of weight. I think airman wants the lighter front axle with the offset rear of the fj's. (the best idea IMO)

Roger.  I'm tracking the weight diff between the two and didn't know it was a consideration. 

I have heard rumor there are a couple years (77 and 78) FJ40 axles have a fine spline (vs course spline) axle shafts.  Fine spline being stronger   

 I wouldn't waste my time with cruiser axle's or mix a cruiser rear-mini front.
 
 If you plan on upgrading to 33's later what's wrong with just running the zuk axle's as they are pretty much built now? I say run what ya got...Put the 4.1's in,add some chromoly's and wheel it.I mean really,how hard are you going to really wheel to justify upgrading to toy's?

thanks oneal your right I just rebuilt both axles and so they should be fine for QUITE some time since im not out to break anything and wheel very softly. I just traded a kid a brand new clutch and flywheel today for 4:16 tcase gears today. So I think I will just finish paying off the axles clean them up with grinding and paint and then trade them off for some stuff maybe rock sliders and a rear bumper or something.

well for now ive decided to sell my 4.16 gears, heater control valve, and full cs130 swap that I have and will get a 3speed to swap into the sami but in the future use I will be putting 4:9 tcase gears to go with my 5.12 diffs, atleast when I decide I need to go higher to 33s or 35s.