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Alluminum underdrive pullies will free up some hp and mpg. I had the BBK ones on my 97gt and as my first mod I swear I could feel the difference. I have never heard about swapping to an aluminum trans. I have heard of aluminum driveshaft, but I haven't ever seen a before and after dyno comparison to back up any claims. I'm pretty sure the case on both the auto and 5 speed are aluminum anyways. Yes a change in rear gears can help mpg. I recemond 3.73, or 4.10, some companies beside FRPP make a 3.90 as well. A custom dyno tune with a tuner will optimize your combo and give more efficient performance. A K&n stlye filter or complete cold air induction kit will also help.
 

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Your wrong. Higher numericaly gears put the engine in a more efficient powerband. Being in this higher powerband the engine works less and is more efficient. Now I'm not saying go out and get some 4.56s and tool down the highway at 3K rpm. I can only speak from my personal expierience. My 97 gt had 3.73s, underdrives, exhaust, and some other bolt ons. I easily got 26 mpg with the a/c blowing going 75 mph on more than 1 occasion. If your thereoy is correct why doesn't Ford go back to 2.73s to avoid the gas gussler tax? With the stock gears at highway speeds the engine is somewhat bogged down and not operating in its most effecient range.
 
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