It would definitely make a HUGE difference if re-gearing! Same change could be made by going with much smaller diameter tires (45 series vs. a 75 series tire).
When re-gearing, shorter gears will give you more torque at the expense of top-end speed.
So, basically, a shorter gear, like going from 3.73 gears to a 4.10 gear set (just as an example and not a specific ratio for a 5th gen) will allow more work from the engine to be applied to the same final turn of the wheels. Instead of 3.73 rotations of the engine to produce 1 turn of the axle, it can now use 4.10 rotations to turn the axle the same, single revolution. More torque, less top end.
So long as you're not trying to drive at 90+ mph all the time, this would help greatly with high altitudes and inclinations while driving over the passes.
Have you re-geared? If you have I won't argue with you since you probably have better experience. I haven't, but theoretically this is what I think will happen. I could be wrong if there are things I haven't considered or bad assumptions.
I don't think it will make much of a difference since you aren't towing and climbing hills in 5th gear. It will make a difference for cruising with less load because you are higher in the power band in 5th gear (higher RPM for the same speed), so you can stay in 5th gear longer.
Edit: After working out the math for this post, my conclusions at the bottom are a bit different than this initial guess.
I found transmission gear ratios here:
http://www.toyota-4runner.org/5th-gen-t4rs/179850-gear-ratios-5th-gen-5spd.html
Other assumptions:
5600 RPM Redline or transmission shift point
Speed is 65mph at 5600 RPM in 2nd gear
Neglect effects of the torque converter
There may be some rounding, minor rounding errors, and or typos below because I'm lazy.
Gear Ratios
1st 3.52
2nd 2.042
3rd 1.4
4th 1.0
5th 0.716
Reverse 3.224
Differential Ratio 3.727
Transfer Case (High/Low) 1.0/2.566 (4x4 SR5, Trail only)
Let's say with stock gearing 2nd redlines (or the transmission shifts at WOT even if it's not quite at redline) at 65mph. Now we can calculate the WOT shift point for each gear:
1: 37.8 mph
2: 65 mph (this is my assumption. It's not exact, but it's close)
3: 94.8 mph
4: 132.7 mph
5: 185.4 mph
The top speed is likely limited to around 115-120mph, so you can re-gear quite a bit and not run out of top speed. Top speed in 4WD Low is also quite high, probably around 60mph. I calculated 72mph, which sounds a bit too high. Maybe one of my prior assumptions is off a bit, but it doesn't matter to think about the effect of re-gearing.
Now let's calculate the engine speed as you accelerate through the gears at WOT:
1: 0 to 5600 RPM | 0 to 37.8 MPH
2: 3257 to 5600 RPM | 37.8 to 65 MPH
3: 3840 to 5600 RPM | 65 to 94.8 MPH
Let's say you re-gear from 3.73 to 4.10. That's actually only a slight change. The ratio between the two is 1.1, so 10% different. Now we can recalculate the numbers above:
1: 0 to 5600 RPM | 0 to 34 MPH
2: 3257 to 5600 RPM | 34 to 58.5 MPH
3: 3840 to 5600 RPM | 58.5 to 85.3 MPH
As you can see the shift points in RPM are exactly the same because the ratio between gears in the transmission is the same. The speed at which it shifts is different because the final drive ratio changed. Let's think about how this affects real world driving situations:
Gears multiply torque, so you have 10% more torque all the time. That's great for accelerating from a stop.
But the transmission has lots of gears, and if you are not starting from a stop and not at WOT it probably has a few it could choose from. I don't know how it works, but let's assume it shifts based on how fast you want to accelerate (it's telepathic, rumored to be in the 6th gen 4runner).
If you're cruising at 55mph stock you'd be at 1661 RPM in 5th. If floor it to pass someone it goes to 4738 RPM in 2nd and you quickly accelerate to 65.
If you are regeared cruising at 55mph you'd be at 1828 RPM in 5th, so you'd have a bit more power, but if you're trying to pass it would still need to downshift. It won't go to 2nd because it wouldn't be able to spend much time there before hitting redline, so it goes to 3rd and you're at 3573. You won't accelerate as fast now, because the engine speed is a lot lower. But the re-gearing increases torque, right? Yes, but it doesn't increase power.
Let's assume that power follows a linear slope proportional to RPM and torque is constant in the normal driving range. Close enough.
Torque is proportional to how fast you accelerate since it's basically a force, and the wheels convert rotational force (torque) to linear force (acceleration). Linear force is basically how hard you get pushed into your seat when you accelerate (though drag takes up more of it at higher speeds). The transmission and gearing multiply torque.
Let's ignore drag (aerodynamics, rotating friction, and anything that increases with speed).
Since we're assuming the torque of the engine is constant, that means the linear force is constant in each gear, and since mass is constant and we're ignoring drag then acceleration is constant. If we arbitrarily assume first gear pushes you into your seat with a force of 1 G (one times gravity. It's actually a lot less but it doesn't matter what it is) we can calculate the acceleration in each gear.
Note: At this point I don't know what my conclusion will be. I have an idea of what I think will happen, but I don't know if the calculations will support it or not.
(stock, WOT, across the entire RPM range)
1st: 1 G
2nd: 0.58 G
3rd: 0.4 G
4th: 0.28 G
5th: 0.2 G
If you're re-geared, multiply everything by 1.1:
1: 1.1 G (a significant improvement)
2: 0.64 G
3: 0.44 G
4: 0.31 G
5: 0.22 G
If you go with 18.75 gearing instead of 4.10 or 3.72 (because it makes the numbers convenient), multiply everything by 5
1st: 5 G
2nd: 2.9 G
3rd: 2 G
4th: 1.4 G
5th: 1 G
Top speed is 37mph
As you can see you accelerate faster in every gear. From a stop you should accelerate faster with lower gearing. (though acceleration doesn't seem that much faster in 4WD low for some reason?)
Let's say you like transmissions, so you add a transmission in front of your transmission with 18.75 gearing to get back to normal top speed. The second transmission will have different gear ratios that a normal one, and I don't feel like figuring out the difference. I think all 5 gears are "overdrive" gears (that is a stupid term).
Now when the first transmission is in 5th the second one acts like normal. the top speed in each gear is:
1: 37.8 mph
2: 65 mph
3: 94.8 mph
4: 132.7 mph
5: 185.4 mph
and the acceleration at those speeds is limited to:
1st: 1 G
2nd: 0.58 G
3rd: 0.4 G
4th: 0.28 G
5th: 0.2 G
The first transmission can shift, too, so you basically have a 25 speed transmission with much lower gearing available than stock, and you can approximate many re-gear options.
The acceleration can be higher than the last set of numbers above since the first transmission can shift too, but only at a lower speed since the engine is at redline at those speeds but for a given speed there is a limit to how fast you can accelerate because the engine can't turn any faster while putting out the same torque. That is the definition of power.
Power is force times speed. The engine's power is limited, so at a given speed there is a limit to how much acceleration force you can get. At lower throttle positions you can have less acceleration at the same speed.
If you re-gear you can get a more acceleration in each gear at the cost of a lower top speed in each gear. You can accelerate from a stop faster in first gear, but after that the transmission has other gears to choose from.
The problem with analyzing this is what people want is weird. If you're towing a trailer up I-70, here are a few things you might want from the engine:
You want maximum acceleration to merge onto the highway and pass slow vehicles.
You want to be able to accelerate some if you change lanes and need to go a bit faster
You want to be able to accelerate without shifting gears because the transmission has some delay and the engine is noisy at high RPM.
If you re-gear 10% lower, here's how it affects each of those things:
Getting to highway speed form a stop is faster, but only up to 58.5mph. After that it's much slower. That is inconvenient because you probably want to go over 58.5 on the highway.
If you're driving 58.5 to 65 you have much less force to accelerate and pass since 2nd is no longer available.
If you're driving at 65-85.3 you have 10% more force to accelerate and pass someone in 3rd. You also have 10% more force to pass in any higher gear without downshifting, which is apparently desirable.
Cruising with light load at any speed the engine RPM is 10% higher, so it is a bit louder.
TLDR? Start here:
So re-gearing seems beneficial overall, but it could cause problems around 58.5-65mph if you don't have enough power to accelerate past that speed in 3rd. It will decrease fuel economy since the engine speed is usually higher, and it might make the engine a bit louder for the same reason.
If you want better acceleration without having to wait for the transmission to downshift and you don't like hearing the engine near redline, then re-gearing would probably help.
If you want to accelerate faster to highway speed, re-gearing won't help or will only help slightly. I think it would help if you had more gears in the speed range where you are trying to accelerate, but normal re-gear options only get you a fraction of an additional gear between 0 to highway speed. You need more power.
If you find that the gear ratios are too wide and your top speed is limited once the engine reaches redline and transmission is forced to shift to the next higher gear, re-gearing won't necessarily help. It depends on drag, the details of the power curve, and other things I neglected in the math above. You need closer gear ratios (more transmission speeds or lower 2nd, 3rd, 4th, and 5th without changing 1st) or more power. That is the problem my Civic had in the mountains.
So why did Toyota pick the factory gearing they did? Probably a few things:
- 2nd gear is placed above 60mph for the all important 0-60 time
- 5 speeds was a lot when they developed this transmission
- It gives reasonable efficiency and a quiet engine at typical highway speeds
- It seems standard compared to other vehicles I've driven. Maybe it was never designed for 85mph highways?
I hope this helps. It's probably hard to follow and it's a lot of math, but it makes sense to me at least.