Went out and did some four wheeling yesterday.
I'm very impressed on how well the pickup did.

The only problem is in the real rough stuff the pickup is just to fast even in the lowest gear.
I ended up riding the clutch until I could smell it.
The 15 point turn didn't help at all.

The truck is geared just right for the freeway, so I don't want to loose that.
1500rpm is a real good engine speed for power but it will pull pretty good at less than 1000rpm.

What is the next step?

1991 Toyota 4x4 with stock drive train and modified motor.

Dual transfer cases or single case with lower gears.

http://www.marlincrawler.com/

http://www.inchwormgear.com/store/

http://www.trail-gear.com/

Remenber, cheaper is not always better.

IMHO, Best way to keep your highway gearing but go slower off-road would be to either change your existing t-case to a 4.7-1 crawl ratio or do dual t-cases.
Dual t-cases would mean driveshaft and floorboard modifications though.
Marlin has options for both.

Todd

What I want to know is which is better and
which is more bang for the buck?

Can I just change gears in the "T" case?

First, you have to figure out what T-case you have. I am assuming that you have a four cylinder since you did not say. If my memory serves me right, there were two cases in the four cylinder in that year but I could be wrong. You need the gear drive case and you can put different gear sets in it. There are 4.0, 4.70, and 5.0. The inside of the t-case has to be milled a bit but it is not that hard to do. The only problem with doing the gear sets is it does not retain the stock low gear in the t-case; you have the normal four WD high range and a very low, low range.

You should really read up on this stuff on one of the web pages I posted. Marlin is the pioneer behind the low gears and the dual case setups. His stuff is all I will use and have been for the last thirteen years without a problem.

I know this is an odd/unpopular suggestion, but another option is to switch to an automatic transmission. Then you can go as slow as you want, just use the break pedal. Can be done fairly cheaply, esp sicne alot of guys dump teh autos.
Downside of course is that the A/T is heavy and sucks up alot of your power, so if you like to accelerate fast, maybe not the best route.

IMO for the best versatility dual cases > single w/ low gears... you have the choice if 1x, 2.2x, or 4.4x reduction.

I agree that automatics are pretty darn good, especially in loose or muddy soil.

What would it take to convert to an automatic?
Wouldn't I need to change the 3rd members to match the automatic?

What would the the cost to do this?

Going to an auto would be my choice too....it's probably so much effort and expense to convert that I would think it would be 'less trouble' to just buy another truck with an auto and switch your preferred stuff over to it...like maybe the custom stereo etc.
Now with the auto you could run let's say, as an example, 33x10.50 tires with 529 gears and probably have a nice comfortable cruiser on the highway and plenty of low speed capability offroad (without any additional transfercase gear changes).
I have run 571 gears in my 1987 22RE Runner auto with 33x10.50 tires....maybe a little too revvy on the highway for some (75 real mph at 3400) but it had plenty of offroad torque and slow speed capability.
ZUK

Actually, from what I understand, the conversionb isn't too bad. 90% are from auto to 5spd... IIRC the biggest PITA in that is cutting the hole in the floor/firewall for the clutch pedal - but if you're going the other way, that's no issue (will have to cover it up I guess).
You'd need the A/T tranny ECU, I *think* the belhousings are the same so that'd bolt up... holes in floor pan/tranny tunny may not be the same, not sure - I know the center consoles are different.
Re: regearing 3rds, not a requirement but probably desired if running anything > 31" tires.
I'd assume you have the stock 4.10 geared 3rds; for auto the stock was 4.30. Not a huge difference really, but if going w/ any real size dtire it'd be sluggish.

I have 5.29s and 33" ProComp XTerains on A/T, I find this combo to be pretty good... I can run 75-80 on highway no problems, RPMs around 3k which is just into the power band (I have LCE headers too). I stil average ~17mpg highway. Prior to this I had 32" ATs on same gears and it was awesome on the road. 5.71s would def be overkill.

I updated my personal info.

I'm running 30x9.5x15 BF Goodrich All-Terrain T/A M/T

This is something to think about.
Do most of the serious boys run auto or stick?

I am getting 20 to 22mpg on a regular basis.