Looking at doing transfer case gears in my samurai i know the 6:4:1 is the best bang for your buck but i am really not a full time rock crawler or anything. Mostly just a hunting rig that goes out on 4wheel drive runs now and then. Im not saying that i will never rock crawl but im thinking the 4:6:1 might be a better all around use gear set.

That will depend on what size tire you will run. I currently have a 30" tire and can go off-roading in 4x4 LOW range, with stock gearing, (86' Samurai). I will probably go with the 4.16:1 in order to gain use of my 4x4 HIGH range and possibly move a 31" tire. Maybe other people can chime in here and give us both some good insight on the proper ratio for our applications!

Take care,
Julian

I put a set of 4:1 T-case gears in a sammy for a friend of mine, after we went out
wheeling in Calico Ca. and he wished he had gone with 6:1 gears, but he also was
running 35" tires so that was also a factor.

IMO I would go with 6:1 if you are 1. keeping the 1.3L engine and 2. going to get
a big set of tires, like 33" to 37", other than that the 4:1s with 30" tires for mild
wheeling should do the trick

Wild

Ya i am running 32 10.50's with tracker gears i think 528s? Not sure on the gears cuz i bought the axels from a friend and cant remember what he said they are. Im thinkin 6:1 might be the way to go but i just dont wanna be to low for mud or snow.

oh ya also looking to put the 16 valve in so take that into consideration

  have 86 sam 1.3 with some engine mods for more torque. run 33/12.50 pro comp xterrin. have 6:4:1 with 4:30 front and rear gears done by trail tough. very happy. daily driver.speedo on the money. cruise freeway 60 no problem. and have done really well with my off road adventures.  ==mudervr

I run the Tracker 5.12 with a 6.5:1 TCase and the same 33x12.5 that mudervr is running.  I only have the 4 speed to go with my 970cc engine but I run around 50mph at just a little over 5K for my RPM's, definitely not highway gearing.  Then again the stock top speed on the 410 is only 62 so the 5th gear would probably help.  With the 16v and 5.12 already in the diffs I'm surprised you need to go lower at all with only 30" tires.

I would just drop in the 4.8 or 4:1 t-case gears, that should be more then low enough.  A club member has the 4:1 and 5.88's with some older 31" Swamper TSL's and can hardly go 60 mph anymore.  Not exactly what you want in a hunting rig. 

This should be close to your current gearing configuration:
http://www.solemnwarning.net/transmission/?id=31

You can change the ratio's in the transfer case to see how each gear set will affect your high and low range speed.