y5mgisi
1 ton status
Funner with a helper! Unless you are dead set on keeping those traction bars, there are better methods out there for controlling wrap without the drawbacks that the rancho bars have.

In all honesty, doubling your milage to 18mpg would be difficult. You would have to keep an overdrive trans, and even then it's going to be tough. My '12 gmc sierra all stock with 3.42 gears and double overdrive trans with active fuel management and variable valve timing gets me 14.5 average. Granted I can get over 20 on the highway but that's with having all the cards stacked in my favor. So maybe if you can put it at a more realistic 15 - 16 you could possibly get it.
Regearing a ten bolt or a Dana 44 to 3.73, 4.10, or 4.56's is a waste of money. There are thousands of 3/4 ton axles with those three choices of gears already in them. Have you looked into finding a 1990 or 1991 NP241 from a K5 or a Suburban? They already have a VSS and they are stronger than an NP208.
Martin

