U.S. Gear Corporation, 9420 Stony Island Ave., Chicago, IL  60617 -- Phone 888-874-3275

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Dual Range

Success Stories

 

 

I have a 1990 Chevy 2500 series Suburban...The original 400 three speed transmission was used in conjunction with a US Gear OD auxiliary. This has been the best thing ever. We have towed a 34 foot trailer across the continent three times, through the Canadian Rockies, Salt Lake City, Grand Canyon, over Wolf Creek Pass (10,500 ft) etc, for a total, so far, of 260,000 kms. Haven't had any problems with either the 400 or the auxiliary transmission. I leave the OD in high range and once in a while select second on the automatic when the Cummins starts to bark back at me. The US Gear unit has certainly been great.

L. Wright
In 1998, I had a U.S. Gear overdrive installed on my 1997 Dodge Cummins with 5 speed manual transmission that was at 37000 miles on truck.  Currently 142,685 miles on vehicle no problem with unit.  We pull 33ft RV, approximate weight of load 12000+.  If the Dodge 5 speed wouldn't keep dropping 5th gear (nut works loose). The 2500 4 wheel drive is great now that I can split 3+4 gear. 4:10 axles reason for overdrive.
D. Elliott
Just a quick note to let you guys know I am still happy with the Overdrive unit I purchased...three years ago.  I have used it for over 50,000 trouble free miles, towing a 52 ft flatbed, loaded, and towing a 30ft 5th wheel RV for extended trips of recreation. The truck, a '96 Powerstroke 4x4 crew cab, has performed better, and run for less fuel, since the day of the installation. The Auto transmission mates very well with the US Gear unit, and I have gotten the art of on the fly soundless changes down real good.. I will have one of these units in every truck I buy, from now on. Thank you for having such a great product.

W. Anderton

After a lot of research and numerous calls to your technical support personnel, I purchased a U.S. Gear underdrive auxiliary transmission.  The unit was installed by myself to a 1995 Chevy 2500, 2 wheel drive, extended cab, 350 engine, 3.73 rear end.  I have been towing a 27-foot fifth wheel trailer for 3 years and was underpowered for long hills and windy days.  I would like to say that after towing over 6,000 miles to Arizona and back, I am very pleased with how the unit improved my towing and gave me the extra RPM or power to climb the long hills and instant shifting to that middle gear without downshifting to the truck's second gear ... I am happy with the unit; it filled my needs at a reasonable cost, and would recommend it to others that need more power without buying a new tow vehicle.

R. Salonek

I just wanted you to know that the U.S. Gear [Underdrive] is beyond what I expected.  I never went over the Tehachapi at more than 35 or 40 in second gear.  Believe this, I went over in Under at 50 to 55 no problem.

J. Feetham

I just installed one of your underdrive units in my 2002 Dodge 3500.  The unit is a good one.  I have recommended it to a couple of fellas on DieselTruckResource.com already.
The installation went very well, about 4 to 4.5 hours all told. Something that anyone with a little mechanical knowledge and a friend to help out can do. I had the drive shafts altered while I did the install and all came together very well.
Thank you very much for a quality product.

R. Reid

First, thanks for the technical advice you provided me for the Dual Range (overdrive) installation into a 1992 Dodge, 2WD, Cummins, Getrag 360, 3.54 differential & exhaust retarder.

We use the Dodge as a second auto and pull a 5th wheel trailer. Since we wanted to keep our 'auto use' economy plus comfortably pull the 5th wheel over passes and use the exhaust retarder in any gear (direct or overdrive), an overdrive that could be used as a 'splitter' was in order.

Although we searched the market for an overdrive and considered several, we seemed to always return to the Dual Range because of its robust construction and the ability to use the exhaust retarder in any gear (direct or overdrive). Our U S GEAR Dual Range Overdrive installation has met both our cruising and hill climbing needs.

Pulling the 5th wheel in 4th OD provides us the rpm range recommended by the Cummins factory engineer, plus the desired cruising speed. Then using 5th OD provides us a similar rpm range for 'auto' interstate driving.

Here is an overview of our installation.

1. The Getrag 360 was converted from a 2WD transmission to a 4WD transmission by replacing the tail stock and the output gear.

2. The Dual Range input gear was replaced to allow it to bolt directly to the rear of the Getrag 360.

3. The output of the Dual Range is bolted directly to a modified NP 205 transfer case we use in low range when backing the 5th wheel trailer.

4. The original two piece drive line was replaced with a new one piece driveline from DriveLines Northwest in Everett, WA.

Although the Dual Range shifting is acceptably quiet, I've designed a microcontroller application to automatically shift the Dual Range -- retirees generally need to 'tinker'.

Initial testing with the clutch disengaged during the (Dual Range) shifting seems to indicate that shifting with the clutch engaged will be done satisfactorily -- time will tell.

Should anyone wish more details about this installation, use my included email address. (Contact US Gear if interested in the e-mail address)

All in all, should we replace the '92 with a new Dodge, a U S Gear Dual Range will be installed in the new pickup.

B. Wills

We installed the underdrive unit in our 1996 Dodge 3500 with an automatic overdrive transmission with the 3.54 rears. It is a 4X4 as well and we have added an extra 100 gallon fuel tank and all the hitches on this club cab so we usually gross out fairly heavy and then as we deliver RVs and boats all over the country, with some of the RVs weighing up to 22K empty, and being 102" wide and up to 44 feet long, we at times felt "underpowered". But the addition of the US Gear underdrive worked out well.

We simply drive most of the time with it in direct and when faced with a hill or a headwind, or for better performance is city traffic such as Atlanta, Nashville, or Indianapolis or any of these like situations, we simply select the underdrive position, and just go about our business as though we had picked up an extra 50 or so horsepower.

We have the 5.9 (359 cubic inch) Cummins diesel, and normally empty we average 23.8 miles per hour. In city traffic, with the underdrive engaged even when empty, (for better performance and control), our mileage did drop 1.8 mpg. However, on three different occasions, pulling the same model 5th wheel from Elkhart, IN to the same location in NH, the average mpg actually increased when we used the underdrive while loaded. Normally we averaged 14. 8 mpg "pulling" prior to installing this unit, but it was extremely difficult to maintain speed with normal hills, even with the Cummins. By the way we have had 5 diesels previous to this one that we installed the underdrive unit on so we have a real good idea of what we are up against. Now with the underdrive installed our average with using it and letting the automatic overdrive transmission select when to shift as necessary, our mileage has actually increased by 1.4 to 2.1 mpg. I think this is due to the fact that the throttle doesn't require being "mashed" to the floor and the tranny being out of OD in hilly travel or windy travel. Folks actually think we have installed a larger engine!!! We have nearly 200,000 trouble free miles on this unit, and it has not given us one ounce of trouble. It shifts normally from direct to underdrive whether we are in New England at 35 - 40 below zero or in Arizona at 110 in the heat.

Now let me give you some operating advice. We were warned or told for a better choice of words, and it is well documented in the literature, that there will be a rather loud "clunk" when you shift in or out of underdrive. At first it bothered me, and then we learned to shift the automatic OD transmission to neutral and then select the auxiliary transmission to either position and then place the main truck transmission back in normal OD. The "techs" that installed ours stated that they were well aware of this but declined to tell folks about it as they did not want to be blamed if someone tried this way and inadvertently placed the main transmission in the wrong gear, which I can understand. But, my wife normally just shifts it in and out by simply selecting which position she needs without worrying about the "clunk".

Basically, it is a real good investment and it is one of the few products that we have purchased in all of our years of delivering boats and RVs that actually outperforms what the sales folks tell you it will. Your truck will really pull just about anything you hitch it to with this unit installed. An added benefit that we have noticed is that it is really great when pulling in slippery snowy conditions, especially along the NY Thruway when the lake effect snows continue and you have better, I mean really way, way better control with the extra rpms, and the slower speeds in 4 wheel drive high position. Four other couples with whom we work with out of Elkhart IN have installed it as well, 3 with Dodge diesels and one with the Ford power stroke diesel and their performance is equally as impressive as ours. Basically, I believe it is because the engine doesn't have to work as hard to keep the "load" moving when the underdrive feature is engaged. Bear in mind that we lose approximately 8 to 10 mph for the same engine rpms that we would normally be operating with in a diesel, and I personally don't like to go beyond 2250 rpms with this engine even though it is normal to go to 2500 rpms or better. That is the old fashioned trucker in me from the big rig days. But, hey, I would rather get the mileage and lose a couple hours and enjoy more scenery, especially at fuel prices as they are today.

In short, I don't think you would go wrong in installing this unit in your Dodge. If it performs half as well with the gasoline engine as it does with the diesel, you can't go wrong.

J. and D. Farnham

Update: Late 2005
Just want to let you folks know that the underdrive we installed in a '96 Dodge Cummins dually is still operating flawlessly with over 400K miles on it. Our son is using it to pull a cattle trailer in upstate NY and loves the fuel mileage and the performance. We thank you again for a great product.

If you have enhanced the performance of your vehicle with the Dual Range Auxiliary Transmission, we'd like to hear from you...and we will feature your story on this page.  We frequently hear stories from performance-minded drivers how a Dual Range has increased their driving enjoyment.  Now you can let everyone know about the benefits of the U.S. Gear Performance line.


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