I've no real preference other then I have new meat/wheels already in a 6 lug.
Being set up for 6-lug, why not get a 6-lug 14bsf as described above? They are found in cargo vans and heavy-half-ton trucks, and would give you the strength you desired without losing your lug pattern. Handy, if you ask me.
The guy ended up flaking on me as i was driving to see it. Just went unresponsive. Oh well. Seems like I wouldn't have known at the time it was wrong for me any how!
No particular reason that you have to use the "right" axle. Lots of us use "wrong" axles, we just had to work a little bit to make them fit. I just didn't want you to think you were getting a bolt-in replacement.
So, talk to me about gearing. What is going to be ideal? I have looked at the gearing to tire size ratio charts out there, but I do a lot of mountain driving with the truck and I am being lead to believe it's a gearing issue, not a lack of power from a tired 350 issue.
Once I hit a steep grade like the pass heading to vail/grand junction from Denver, I can't break 40 MPH in a 75 MPH zone.
A 6-lug Suburban, IIRC, should have a 700R4 O/D tranny (lemme know if you have something odd-ball). 3.42 is a fine gear ratio for this, but you will be pretty slow with the 33" tires. I'm betting the CK5 consensus will be to recommend that you get 4.10 gearing for your current configuration. Being a fairly patient driver, my answer would be 3.73 gears.
Switching to 35" tires I'd change gearing down another notch (4.10 or 4.56, depending on your driving style). That should give you LOADS more available power, solving your 40MPH problem. If not, we'll recommend engine upgrades!
Axle upgrading is a *great* time to switch up your gearing, as you can get your new axle with your new ratio. So play around with your gearing numbers, figure out what you want, and then go shopping!
As said above, you may find lower gearing more widely available in 1-ton axles, but they do exist in 1/2-ton and 3/4-ton configurations. And having a 10-bolt front, it's easy as pie to change the lug pattern if you decide to go 8-lug.
