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have completed setup of the 3.73:1 gears in my DANA
44   (Read Only Topic)

MIKER
Senior
Member

815 posts [100%]
Tolar, Texas

I have completed
setup of the 3.73:1 gears in my DANA 44

1:37
PM 12/2/2001

I have not completely re-assembled it because I
am waiting on a part but I think that the worst of it is
done.
It will be a while before I can test them out because
my transmission may not be ready until late December or early
January. I'm thinking about going through my rear wheel
bearings "while-I'm-at-it".

I used the following parts:
Rear end rebuild kit
80-82 PN# 5542 ($89) http://www.bairs.com/
SPICER DANA ring
and pinion, 3.73:1 ($141) http://www.tomsdifferentials.com/
4 - GM
gear lube PN#1052271 ($5.10 each)
1 - GM additive
PN#1052358 ($5.03)
1 - GM Gear Marking Compound PN#1052351
($3.38)
1 - 12 pack of beer ($10.00)

I used the following reference material:
- GM
Shop Manual for 1980 Corvette ST364-80 Section 4B "Rear
Axle".
- SPICER DANA Ring Gear and Pinion Tooth Pattern
Interpretation (included with gear set).
- Yukon Gear &
Axle Installation Kit Instructions.http://www.ring-pinion.com/yukon-instructions.pdf
-
Randy's Ring & Pinion "Tech Library" http://www.ring-pinion.com/home.html

I used the following tools:
1- 10-40 in/lb.
Torque wrench
1- 16-80 ft/lb. Torque wrench
1- 50-250
ft/lb. Torque wrench
1- 1" Micrometer
1- Bearing
puller
1- 12 pack of beer
1- GM gear marking compound
PN# 1052351
1- 18" Pipe wrench (for holding yoke while
tightening pinion nut)
1- Bearing race installer (home
made)
1- Big hammer
1- Differential housing holding
fixture (home made for use with engine stand)
Obviously
quite a few other tools were used but this is a list of the
essentials.

My final specifications vs. reference
specifications:
Pinion Pre-load - The GM manual called
for 15 to 35 in/lb. and the Yukon guide called for 14-19
in/lb. My actual results were 18 1/2 in/lb.
Back
Lash- The GM manual states "Backlash tolerance is 0.005" to
0.009" and cannot vary more than 0.003" between points
checked. The Yukon guide showed 0.006 to 0.010". My actual
results based on the four locations that I checked were
.007, .006, .006, and .005 .
Pinion depth / Gear
contact pattern- The GM manual specifies the use of Pinion
Depth Gauge Tool but the DANA SPICER instruction says to use
the GEAR CONTACT PATTERN METHOD and not to use the gauges.
Below are pictures of the contact pattern on my gears along
with comparison charts. The pictures are not real clear but
let me know if any of you see a problem with the pattern on
my gears vs. the reference guides. I was fortunate in that
I started out with the original shim pack values and the
contact pattern looks just fine to me. The only real trouble I
had was trying to find an acceptable shim pack combination for
the pinion pre-load but at least that bearing is not pressed
on!

Due to wear on the differential shaft from the inner yoke
shafts, I have ordered a new one. This will delay completion
until it arrives via UPS. Combined, the wear on both sides of
this shaft was equal to .025". Replacing this shaft should
eliminate a considerable amount of the .014" (left side) and
.015" (right side) inner shaft yoke play that I had in the
beginning.
I have decided to just clean up the ends of my
yoke shafts and re-use them as they are. I was going to test
the hardness on the ends of the shafts but the guy who runs
that particular lab at work was off all last week. I'm also
not replacing my clutch pack because it still works fine, I'm
too darned cheap and I don't have the required tools.

[Modified by MIKER, 3:39 PM
12/2/2001]
_______

1980 black on black,
388/700R4/3.73

Mike69
Senior
Member

3700 posts [100%]
Voorhees NJ

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

3:17
PM 12/2/2001

Cant answer your q about the pattern... but
nice job! and great post!
_______

Gordonm
Senior
Member

2202 posts [100%]
Marlton NJ

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(Mike69)

3:41
PM 12/2/2001

Mine is almost done also. I like your bracket
for the engine stand. I was able to mount mine on the engine
stand also but it does not look as good as yours.

_______

72 Red LT1 Convertible. AFR 190 heads,
Hooker Headers Jet Hot Coated, custom 2 1/2 exhaust with 50
Series Delta Flow Flowmasters, Comp Cams 294S, Crane HI6
Ignition, 750 DP Holley, Vette Brakes Suspension, 3.70 gears
Best time 12.70 at 110 Marlton NJ

Homepage http://corvetteforum.net/c3/gordon72/

81vette
Senior
Member

223
posts [100%]
Humble Texas

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(Gordonm)

4:45
PM 12/2/2001

Miker,

Was the Dana 44 the stock unit for an 80-82 Corvette, or
did you install this from another year
car?
_______

1981 Red/Red.
350 SB, 4 speed, 2.72 gear, 3070
lbs.
VBP Street/Slalom Suspension System.
VBP Stainless
Steel Brakes.

415 SB in the build-up phase.
Tremec TKO 5-speed waiting
on 415 SB completion.

gkull
Senior
Member

3569 posts [100%]
383 road racer
nevada

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

4:51
PM 12/2/2001

All I can say is

When I did the calc. for max MPH with a given tire dia. I
had to have 4.11 for Nevada open road racing. Speed gun tested
at 174 @6500 Now I went for the 7500 rpm motor and bigger dia.
The best thing is 3.90. I drive my car. Once you get up around
7000 rpm your going fast. 700R4's impress the passenger when
you shift at to fourth at 130 mph.

390 is the best comp. I'm going to to do
it.

Stingy74
Senior
Member

2312 posts [100%]
Eh, Aboot, Hoser, etc...
Regina, Sask. Canada

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(gkull)

6:53
PM 12/2/2001

GKull, if you can really hit 7500 in OD with
the 3.90 that will be over 200mph! Let me know when you're
gonna be goin that fast so I can come watch!!
_______

E-Mail me here
Pictures here
Autocross Video
130mph blast video!

MIKER
Senior
Member

815 posts [100%]
Tolar, Texas

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(81vette)

3:43
AM 12/3/2001

quote:

Miker,

Was the Dana 44 the stock unit for an 80-82 Corvette, or
did you install this from another year car?

Yes, the Dana 44 is the stock unit for 80-82.

quote:

All I can say is
When I did the calc. for max MPH with a
given tire dia. I had to have 4.11 for Nevada open road
racing. Speed gun tested at 174 @6500 Now I went for the
7500 rpm motor and bigger dia. The best thing is 3.90. I
drive my car. Once you get up around 7000 rpm your going
fast. 700R4's impress the passenger when you shift at to
fourth at 130 mph.

390 is the best comp. I'm going to to do it.

gkull,
I would have gone with the 3.90s too but it
requires changing the carrier to use it with the DANA 44. 3.90
would be a great gear to have!

[Modified by MIKER, 5:46 AM
12/3/2001]
_______

1980 black on black,
388/700R4/3.73

MIKER
Senior
Member

815 posts [100%]
Tolar, Texas

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

11:20
AM 12/9/2001

I received my new differential case shaft from
Bair's and completed assembly. After installing the inner yoke
shafts, I have no endplay at all. NADA, ZERO, ZILCH. I have no
idea how that occured???
As I said at the top of this
thread, I had .014 on one side and .015 on the other before I
started tearing it down. The carrier shaft had worn on two
sides a total of .025. That explains all but .004 of the
combined end play. Where did the rest of it go?
I had no
problem reinstalling the snap rings onto the yoke
shafts.
I'm not going to worry too much about it.
I
even drilled and tapped a hole into the bottom of the
differential case to make future oil changes easier.

Last night I tore down the passenger side rear wheel
bearing / spindle assembly. To inspect/rebuild. The drivers
side was done 5 or 6 years ago. I will probably go ahead and
rebuild all of the calipers while waiting for the transmission
to be rebuilt.
_______

1980 black on black,
388/700R4/3.73

bence13_33
Senior
Member

2109
posts [100%]
Clymer PA

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

12:42
PM 12/9/2001

Miker:
Nicely Done! Rebuilding a
differential is definitely WAY out of my league right now.
Nice post and pictures.
_______

Coming On 3-31-02: 468 Big Block
'76 Flame Orange Coupe/Black Leather
Interior
My Home Page: http://temp.corvetteforum.net/c3/bence454

gkull
Senior
Member

3569 posts [100%]
383 road racer
nevada

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

5:26
PM 12/9/2001

All I can say is the beer was to much! Today i
had friends over for football and BS. I picked up Bud, Coors,
miller for $8.99 18 packs and one corona 12 pack for $7.99

What you doin to the tranny?

MIKER
Senior
Member

815 posts [100%]
Tolar, Texas

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(gkull)

4:26
PM 12/10/2001

quote:

All I can say is the beer was to much! Today i had friends
over for football and BS. I picked up Bud, Coors, miller for
$8.99 18 packs and one corona 12 pack for $7.99

What you doin to the tranny?

gkull, no doubt, I paid WAY too much for the
beer at a local convienience store!!!
My 700R4 is getting a
rebuild / upgrade. When it is done it's performance should be
more in line with what I am looking for. Firm shifts and
extreme durability.
Here is a partial list of what it will
have in it.
>Replace the 2000-2200 stall converter with
a 2500-2700 converter. (Any of you guys need a 2000-2200 stall
converter with only 1700 miles on it?)
>Return to using
the existing OEM torque converter lock up control system (vac.
switched) that was used with the previously installed TH-350C.
Currently, lockup is based on line pressure.
>3-4 WOT
up-shift kit
>Corvette servo
>Upgrade the pump
rotor with a custom made hardened steel one.
>Increase
overall line pressure significantly.
>Modify the shift
points.
The transmission builder has a large list of
modifications planned. I know so little about it that much of
the terminology is over my head but I feel like he under$tand$
what I am looking for and I know that he is capable of
delivering it.
I'm not asking for much, I just want it to
shift hard and last FOREVER!

Mike69, Gordonm, and Bence,
Thanks for the
compliments! I just hope that this information will be
usefull to someone in the future.
Bence, I seriously doubt
that rebuilding a differential is "WAY out of your league".
You may lack the proper tools but I'm sure that you could do
it if you wanted to.

_______

1980 black on
black, 388/700R4/3.73

zwede
Senior
Member

1974 posts [100%]
Plano TX

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

5:02
PM 12/10/2001

Mike,

congrats on a job well done. I have set up a few ring &
pinions, and as long as you get a quality set, I found the
stock pinion shims will work. The exception is richmond gears.
They seem to make noise no matter what.

As for your pattern, it looks excellent. Notice how it is
centered in the up/down dimension. You may think it should
also be centered in the in/out dimension, but mine have always
come out off-setted slightly outwards, like yours.

_______

Markus Strobl

1971 Coupe, LS-5 454, Muncie M20 4-speed. 490 hp, 554
ft-lbs. Red on Saddle.
Edelbrock Aluminum heads, Roller
Cam, Super Comp Headers, Multipoint EFI, 17" Ralleys.
http://www.corvetteforum.net/c3/zwede

Strike3
Senior
Member

224
posts [100%]
Granbury, TX

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

5:19
PM 12/10/2001

Hay Miker!!
I'll probably use your string,
here, as a bible when I get that far. I'm going the same route
and may use your trans builder if he's agreeable. Keep us
advised as to cost and satisfaction, and thanks for the great
entry!
_______

Strike3

ZD75blue
Senior
Member

3472 posts [100%]
NC,USA

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(Strike3)

5:37
PM 12/10/2001

Gkull think of what you could do with a gear
vendors overdrive at that speed... talk about fast, and your
car would be idle at the same 174... steps back and says dang
gotta get me one a those, adding to list

ZD

gkull
Senior
Member

3569 posts [100%]
383 road racer
nevada

Re: I have
completed setup of the 3.73:1 gears in my DANA 44
(MIKER)

7:01
AM 12/11/2001

Over the years I have all kinds of variations
of 700R4's. Full manual with manual lockup in all gears. auto
with lockup in all gears. As much as 3800 stall converters.
But now I've settled on what I think is the best. Manual
lockup (toggle switch) auto with two set of govenors. so for
everyday driving I have the 5000 rpm auto shifter and the race
day 6800. With a 9.5 inch 3000 stall 3 clutch lockup.

Before you button up the 700 ask about 1/2 line lockup
selinoid. I have had to replace TC just because the lockup
clutch blows out. So the 1/2 (stock is 3/8th)smashes the
plates together with more force - saving the clutch or
clutches

The reason I have gone to 3 clutch (5&7 are available)
is because. OEM and low end converters have @ 19 sq inches of
clutch holding surface. higher end singles have about 24 sq
inches. 3 clutch has 38 sq inches and I run the tranny with
80-100 pounds over stock
psi.

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