Ok you mechanics and engineers and physics buffs

i have always wondered this.

When i am in 1st gear at say 4thousand RPMS it feels like the transmission is under a lot more stress then when in 5th gear at 4k, rpms. Am i on the right track? the higher the gear the larger the physical gear..right? so small pinions are under higher stress at higher rpms then larger gears at the same RPM..right?

Also, is the engine under the same amount of stress in 1st gear@4k then in 5th gear@4k

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Regarding gear physical sizes, think of a derailler gearset on a ten-speed bicycle. 1st gear is the largest sprocket and fifth is the smallest. Basic gear ratio relationship.

As for stress, hard to say. I would propose:

In 1st gear, the stress should be in the case as it strains against chassis distortion caused by the large torque multiplication. 4th gear should strain the gearset and clutch since there is little torque multiplication. Why? Imagine moving a weight with a lever. Lever length is engine torque output (constant), your hands are the gearset/clutch and fulcrum placement equals gear ratio. As the fulcrum move closer to you (gear ratio gets taller), you must exert more force to move the weight, so this puts more stress on your hands.

HTH