fish2keel

Hey guys,

I'm out of ideas of where to look, so I thought it would be best to post. I am using a dana 44 irs from a manual 89-91 C4 into another pony car. It currently has 3.03 gears I believe in it.

My delima is I'm looking to put a good amount of power through it, with a tr6060, for roll racing, not from a dig. It's going to have toyo r888 tires as well.

I've seen post of a Tom's custom diff but when I reached out to Tom's they said they dont do customs. I am open to all options.

Thanks!

Kevova

What are you asking?

fish2keel

I am asking, what are the options and places to upgrade the dana 44?

Kevova

[QUOTE=fish2keel;1601119273]Hey guys,

I'm out of ideas of where to look, so I thought it would be best to post. I am using a dana 44 irs from a manual 89-91 C4 into another pony car. It currently has 3.03 gears I believe in it.

Dana 44 8.50 inch gear. IRS required? Gear ratio depends on intent 3.75-4.10 fill most needs. Posi or True Trac again intent. D44 IRS parts are different from straight axle (truck) parts.

fish2keel

[QUOTE=Kevova;1601121553]i have heard the straight axle and irs have different parts. I have the IRS in the car based on the needs of the car, so moving to a straight axle isnt a real option at this time.

Are there any places that are doing upgrades still to "bullet proof" the dana 44 IRS?

383vett

Unfortunately, Tom Watt, the founder of Tom's Differentials passed away is 2018. Not sure who is running the shop now.

fish2keel

Oh that is very sad, I didnt know. The customer service rep said they dont do custom parts for the c4 anymore. That's unfortunate indeed. Unsure where to turn now for upgrades.

Gale Banks 80'

Trackdogg here on this web sight built mine a number of years ago. Steel Billet Caps can be fitted and close attention to detail is pretty much what is done to the IRS Dana 44. Very few parts are interchangeable with the C3,C4,or Viper Dana 44 all three of them are similar in design but that's it. The 4x4 Dana 44's is yet another set of parts. The Dana 44 is well established Family that never had any Twins.

93 ragtop

If you do a search under user name, rklessdriver, he did a write up on how to keep the D44 alive. Shows how to limit axle travel, how to check clutch wear, etc. I will try and find the link and post it here latter today.

fish2keel

Any source for the billet caps?

Gale Banks 80'

No. The Billet Caps need to be fitted to the Housing. Then once fitted then everything needs to be machined. Its not a simple matter of bolting on stronger Caps. Somebody who has the ability to do this type of machining could also make the Caps. Its not like there are many people interested in having this type of work done, so with little demand, I doubt anybody is making the caps.

JoBy

https://www.corvetteforum.com/forums...r-section.html

If you have the money to spend

fish2keel

Gale, do you recommend any shop that in particular that would do the machining work? I'd be interested in this.

Kevova

Newman Car Creations, now out of business, made a HD batwing if you could find one. Newman was in to C4 suspension on tri 5 Chevys. Using a waterjet a plate could be fabbed to keep the caps from being forced back; spreading the load on the entire assembly.

JoBy

My little winter project ...

scorp508

Ugh... that's sad to learn.

mackeyred96

I could never make a D44 last in my C4 with just minimal power! Half shafts, u-joints, and spindles would break with regularity! Eventually went to a solid rear!

Gale Banks 80'

If You search "12 bolt conversion" in the C2 C3 section you will find people who can do it. A 12 bolt conversion also gets new Caps in addition to a lot more. And no, a 12 bolt conversion can not be done to a Dana 44.

JoeNova

I'd think that it would be fine from a roll. You're not putting nearly as much stress on it as a launch.

C409

..... Joby , this is a very nice looking set-up … any chance that you'll be marketing this ? I'd be interested in one …..