What size tyres are you running? I found, on my recent outback trip with the 255/70R16s Cooper STTs on 16x8 rims, that the KJ struggled even with the GDE Full torque tune. The larger (and heavier) tyres and rims were hitting the gearing pretty hard, not to mention the slight increase in frontal area drag, and the EGT gauge was showing that I was running more fuel (and thus higher temps) to try and achieve the speed to keep up with the others. I try to hold EGT down to 1000F as a peak, and have my gauge alarmed for that, so it was necessary to turn overdrive off often just to keep below that temperature.
Regearing the final drive ratio down to 4.10 would help get out of the torque hole and push the revs up into the meaty part of the band all the time (and thus allow you to run with the 5th ovverdrive on) but you will pay a price in other ways (like fuel economy).
I was getting 14 and 15L/100 with those tyres and with the smaller 245/70s I can get 12's so it's pretty clear to me to leave the big tyres at home when I am towing.
Re the GDE Turbo upgrade, there are a fair number of these running around in the US now, but I don't know of anyone that has done it here. I have thought about it but it makes the vehicle even more exotic in terms of service and maintenance, and potentially hard to sell if you expect to in the future. There is also some welding to do on the cast exhaust manifold to make the new turbo mount fit, so it's not an easy upgrade.
Re-gearing is certainly cheaper. Yukon make a 4.10 set for the 8.25 rear end and the 30A front (I think) but check carefully. Morris 4x4 in the US seems to stock gears sets for both diffs as does JBA. Cmohr is running 4.10s I think, maybe PM him for some advice.
Last edited by glend; 29-04-2013 at 11:16 AM.
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