by Trail X » Wed Feb 15, 2012 2:14 pm
This is a rather complex subject, a lot of which is opinion and based on your driving style.
I went through this same issue when I got new tires. My final conclusion was that I did not want 33s with my 3.41 gears. But it was largely a personal decision.
I'll try to run down my thought process real quick. A lot of which has to do with the locking of the torque converter lock-up clutch (TCC) (if you don't know what that is, look it up).
I've found that if I control my MAP (manifold air pressure) to about 0.4psi below ambient or less when traveling at highway cruising speeds, the TCC will remain locked. This limits your power output from the engine due to engine RPMs. For me, with 32s, and 3.41s, the engine will be around 1600 RPM at approx 65mph (gps speed, not speedo). This is enough power output to cruise comfortably at 65 with flat roads. However, you're loading the engine a good bit to produce the power required to overcome the wind resistance.
Now, add an incline... engine loading comes to near 100% (14.2 psi MAP at ~ sea level). Depending on the slope, you can maintain speed, but more often than not, you'll find your speed decreasing (if you're controlling the throttle to 0.4psi below ambient). Or, you'll try to get a bit more power out of the engine, and the TCC will unlock, giving you an increase of ~400-500 rpm. At that point in the torque curve, you may be getting enough power to maintain speed or speed up, but at the cost of increased transmission temperatures, and lowered efficiency.
Detailing the efficiency loss, I've found a hill that I can barely maintain speed at 60 mph with the TCC locked. With the TCC locked, I get about 14.5mpg instantaneous. That same hill, same speed, TCC unlocked, efficiency drops to about 10.5mpg instantaneous. (For reference, same speed in 3rd gear, TCC locked, I get approx 10.0mpg).
Personally, I plan to regear to 4.10s when possible, before upping to 33s. However, it's all in how you drive, what efficiency is ok, if you're ok with adding a trans cooler, how attentive you are to the engine and transmission's shifts, etc etc.
Hopefully that answers more questions than it creates.
(Keep in mind that these observations have been made with a RTT/parachute on top of the truck.)