Interesting points Kevin, you are right, just because the fifth gear on a KM145 fails does not mean it was over tightened. The are still inherantly weak because the gear is pretty thin. So do you think they would be better off with a .79 5th gear ratio like the FM145 found in the Ford Ranger instead of the .856 found on the KM145? I have never run a stregthening pan, but I did buy a Tuff Pan yesterday for my new FM145 because I will be running a 5:1 Atlas I want to reduce the flexing as possible.
Like I said, I have never had an issue with the KM145 but I hear alot of horror stories. I push about 200 ft lbs of touque and I also run large tires but the original tranny lasted 275K miles which I find to be acceptable. The reason I replaced it was because I took it swimming and I had a small tear in the spring cover boot. It never failed or made funny noises, but I figured it was smart to swap it out when I replaced the clutch because I had a rebuilt tranny lying around.
I also follow a few rules of thumb that I never use 5th gear below 55 mph or while going uphill. I also only use synthetics. But most importantly I also don't let the wife drive it. I try to avoid putting any undue stress on the over drive gear.
1985 Mitsubishi PU 2.3 Turbo Diesel, 13" lift, Watercooled turbo, 4D56 Head, Atlas II,Fox Coilovers, Elockers,
1983 Mitsubishi PU 2.5 Turbo Diesel 4x4, fully restored
2003 G500, sliders, beadlocks, roofrack, ladder etc.
Edited by spencevans (07/15/10 12:07 AM)