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I confused.........why are you guys recommending a lower gear for the overdrives? The 700r4 has a lower 1st gear than the non-OD (th350/th400) already and then you are giving away the advantage of the overdrive with a lower final drive ratio.
If you are concerned that 4.10 is marginal as far as standing start acceleration with a non-OD trans, then the lower 1st gear of the 700r4 should compensate for that. Plus you gain the highway overdrive. If you go too low in the rear you don't get much use of 1st gear. It shifts out too fast and the overdrive becomes no different (RPM wise) than your non-OD trans would have been with the higher gear.
Pinion head diameter is not the weak point.......they are all using the same size bearing. The weak point is the area where the pinion head meets the inner bearing. There is actually less leverage applied to that area with a smaller diameter pinion head.
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