>Alright, I have a question here. I am planning on gettin some Toyota axles with 4.30 gears in them from a local Zuk friend of mine.
Keep in mind that the toyota axles have a centered diff. We get alot of calls from guys who have gone toyota and are looking for ways to get rid of vibrations on their rear end. Axle gearing may be the least of your worries if you want to get high speed going on a toyota rear axle. For the trail though... great!
>I CURRENTLY run 31" tires, but desperately need to upgrade. With that axle setup, would 4.16 gears be too much if I wanted to use it on the highway?
You'd be running higher RPMs than what is ideal, but it should be too bad. Keep in mind that some 31's are more like 32's and some are like 30's. Tire choice can have alot ot do with it too.
>Also, I plan on retiring the Samurai from the street and make it into a soul off-road truck only. With those 4.30 axle gears in, how would 6:1 t-case gears hold up to trailriding/rockcrawling?
Not to put the other gears down because they do work well too, but 6:1 gears are built beefier than any of the 4.16, 4.89, 5.8 gears out there. The tooth pattern is larger for more metal contact per tooth than the other gears. This makes them stronger as well as the alloy being a higher grade. If you turn your Zuk into a rockbuggy with 35's, the strength of your 6:1 gears will be something you never have to worry about.