Camper shell weight/drag is insignificant.
Mine actually gets better hiway mpg with the hi-rise cap on.
I vote go straight to 4.10s.
My 2000 3.0 4wd MO5D regularly gets over 360 hiway miles per tank (19.5 gal tank, usually put about 18 gal in). I typically don't use 5th gear unless I'm over 60 mph. Gets BETTER mpg that way (trust me, I bought it new). The only real change I made is 235/65-16 tires, which are somewhat smaller than the stock 245/75-16s that it came with.
The smaller tires do log more miles than actual, I believe the change was 8.7%.
times.
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DML Tire and Wheel Calculator Results
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Dimensions
Dimension Tire A: 245/75 R 16
(30 x 9.65 x 16) Tire B: 235/65 R 16
(28 x 9.25 x 16) Difference
Width
Sidewall height
Overall height
Circumference
9.65" (245.00mm)
7.23" (183.75mm)
30.47" (773.90mm)
95.72" (2431.28mm)
9.25" (235.00mm)
6.01" (152.75mm)
28.03" (711.90mm)
88.05" (2236.50mm)
-0.39" (-10.00mm)
-1.22" (-31.00mm)
-2.44" (-62.00mm)
-7.67" (-194.78mm)
Speedometer Error
Actual Speed Indicated Speed with Tire B Speedometer Error
5 mph (8.04 kph) 5.44 mph (8.75 kph) +0.44 mph (+0.70 kph)
10 mph (16.09 kph) 10.87 mph (17.49 kph) +0.87 mph (+1.40 kph)
15 mph (24.13 kph) 16.31 mph (26.24 kph) +1.31 mph (+2.10 kph)
20 mph (32.18 kph) 21.74 mph (34.98 kph) +1.74 mph (+2.80 kph)
25 mph (40.23 kph) 27.18 mph (43.73 kph) +2.18 mph (+3.50 kph)
30 mph (48.27 kph) 32.61 mph (52.47 kph) +2.61 mph (+4.20 kph)
35 mph (56.31 kph) 38.05 mph (61.22 kph) +3.05 mph (+4.90 kph)
40 mph (64.36 kph) 43.48 mph (69.97 kph) +3.48 mph (+5.61 kph)
45 mph (72.41 kph) 48.92 mph (78.71 kph) +3.92 mph (+6.31 kph)
50 mph (80.45 kph) 54.35 mph (87.46 kph) +4.35 mph (+7.01 kph)
55 mph (88.50 kph) 59.79 mph (96.20 kph) +4.79 mph (+7.71 kph)
60 mph (96.54 kph) 65.23 mph (104.95 kph) +5.23 mph (+8.41 kph)
65 mph (104.58 kph) 70.66 mph (113.69 kph) +5.66 mph (+9.11 kph)
70 mph (112.63 kph) 76.10 mph (122.44 kph) +6.10 mph (+9.81 kph)
75 mph (120.67 kph) 81.53 mph (131.18 kph) +6.53 mph (+10.51 kph)
80 mph (128.72 kph) 86.97 mph (139.93 kph) +6.97 mph (+11.21 kph)
85 mph (136.76 kph) 92.40 mph (148.68 kph) +7.40 mph (+11.91 kph)
90 mph (144.81 kph) 97.84 mph (157.42 kph) +7.84 mph (+12.61 kph)
95 mph (152.85 kph) 103.27 mph (166.17 kph) +8.27 mph (+13.31 kph)
100 mph (160.90 kph) 108.71 mph (174.91 kph) +8.71 mph (+14.01 kph)
105 mph (168.94 kph) 114.14 mph (183.66 kph) +9.14 mph (+14.71 kph)
110 mph (176.99 kph) 119.58 mph (192.40 kph) +9.58 mph (+15.41 kph)
115 mph (185.03 kph) 125.02 mph (201.15 kph) +10.02 mph (+16.11 kph)
120 mph (193.08 kph) 130.45 mph (209.90 kph) +10.45 mph (+16.82 kph)
125 mph (201.12 kph) 135.89 mph (218.64 kph) +10.89 mph (+17.52 kph)
130 mph (209.17 kph) 141.32 mph (227.39 kph) +11.32 mph (+18.22 kph)
135 mph (217.22 kph) 146.76 mph (236.13 kph) +11.76 mph (+18.92 kph)
140 mph (225.26 kph) 152.19 mph (244.88 kph) +12.19 mph (+19.62 kph)
145 mph (233.31 kph) 157.63 mph (253.62 kph) +12.63 mph (+20.32 kph)
150 mph (241.35 kph) 163.06 mph (262.37 kph) +13.06 mph (+21.02 kph)
155 mph (249.40 kph) 168.50 mph (271.12 kph) +13.50 mph (+21.72 kph)
160 mph (257.44 kph) 173.93 mph (279.86 kph) +13.93 mph (+22.42 kph)
165 mph (265.49 kph) 179.37 mph (288.61 kph) +14.37 mph (+23.12 kph)
170 mph (273.53 kph) 184.81 mph (297.35 kph) +14.81 mph (+23.82 kph)
175 mph (281.57 kph) 190.24 mph (306.10 kph) +15.24 mph (+24.52 kph)
180 mph (289.62 kph) 195.68 mph (314.84 kph) +15.68 mph (+25.22 kph)
185 mph (297.67 kph) 201.11 mph (323.59 kph) +16.11 mph (+25.92 kph)
190 mph (305.71 kph) 206.55 mph (332.33 kph) +16.55 mph (+26.62 kph)
195 mph (313.75 kph) 211.98 mph (341.08 kph) +16.98 mph (+27.33 kph)
200 mph (321.80 kph) 217.42 mph (349.83 kph) +17.42 mph (+28.03 kph)
If your speedometer has been calibrated for 245/75 R 16 (30 x 9.65 x 16) tires, replacing them with 235/65 R 16's (30 x 9.25 x 16's) would result in the speedometer reading high by 8.71%.
Odometer Error
Actual Mileage Indicated Mileage with Tire B Odometer Error
1 mi (1.61 km) 1.09 mi (1.75 km) +0.09 mi (+0.14 km)
5 mi (8.04 km) 5.44 mi (8.75 km) +0.44 mi (+0.70 km)
10 mi (16.09 km) 10.87 mi (17.49 km) +0.87 mi (+1.40 km)
50 mi (80.45 km) 54.35 mi (87.46 km) +4.35 mi (+7.01 km)
100 mi (160.90 km) 108.71 mi (174.91 km) +8.71 mi (+14.01 km)
500 mi (804.50 km) 543.55 mi (874.56 km) +43.55 mi (+70.06 km)
1000 mi (1609.00 km) 1087.09 mi (1749.13 km) +87.09 mi (+140.13 km)
5000 mi (8045.00 km) 5435.45 mi (8745.65 km) +435.45 mi (+700.65 km)
10000 mi (16090.00 km) 10870.91 mi (17491.29 km) +870.91 mi (+1401.29 km)
50000 mi (80450.00 km) 54354.54 mi (87456.45 km) +4354.54 mi (+7006.45 km)
100000 mi (160900.00 km) 108709.08 mi (174912.91 km) +8709.08 mi (+14012.91 km)
Same as with the speedometer, if your odometer has been calibrated for 245/75 R 16 (30 x 9.65 x 16) tires, replacing them with 235/65 R 16's (28 x 9.25 x 16's) would result in the odometer reading high by 8.71%.
Effective Gear Ratio Change
Rearend ratio with 245/75 R 16's Rearend ratio with 235/65 R 16's
4.10 4.46
As far as gearing goes, if you have a 4.10 rearend and 245/75 R 16 tires (30 x 9.65 x 16), changing to 235/65 R 16's (28 x 9.25 x 16's) would be the same as if you kept your current wheels and tires but changed your rearend gears to 4.46's
http://www.dakota-truck.net/CGI-BIN/TireCalc.cgi <for calculations.