Hello! I hope someone out there can throw me a lifeline...

I dismantled the rear suspension of my 1990 Corvette Convertible to put new on polyurethane bushings and a C6 ZO6 brake upgrade. In the process I discovered major play in the half-shafts. A slight tug pulled them out of the differential. The C-clips are missing! I pulled the cover off the differential and removed several chunks of the clips. Oddly, after very close inspection of the gears, there is no damage to anything! How is that possible?

I need to know if anyone can give me exact dimensions of the C-clips? I have looked everywhere to no avail. I found a place called Tom's Differentials who sells a kit, but do I really need $40 worth of them?

There is another dynamic to this that makes time a big problem! I'm trying to find clips locally but I have no idea what size they should be. Please help!

Also, can anyone chime in with the very best differential fluid to use? Regardless of price, what's the best?

Thank you in advance.

 

Assuming. a Auto with a Dana 36?

 

I am so scattered! It's a Dana 44 with manual 6-speed ZF.

Thanks for kicking me into gear.

 

Sorry!!! to hear that. Thankfully you did not find damage!!!
I have a spare Dana 44 I rebuild the clutch packs last summer. I will look at the clips when i get home.
I would use Lucas climbing. along with the limited slip additive.

 

I've never heard of Lucas climbing. I'll look into it.

Thanks for checking on the clips if you can. Hopefully I can find them locally.

 

Yes, the gear lube is very popular!! Walmart even carries some of there pruducts!! Sorry. Someone will need to complete the Snap-ring dimensions. Mine is .083 thick. You should measure your axle channel to determine how much thicker you need. It is to tight to measure with dial calipers. The snap-Rings are extremely strong. High quality steel. You need "HD"snap ring plies to install / remove them!!! I recommend a threaded adjustment style.. Do not purchase cheap Snap rings. I believe ZF doc. has a quality Snap ring thickness selection.

 

[QUOTE=THE 383 admiral;1591721196] You should measure your axle channel to determine how much thicker you need. It is to tight to measure with dial calipers. The snap-Rings are extremely strong. High quality steel. You need "HD"snap ring plies to install / remove them!!! /QUOTE]

there are a few thickness c-clips so you need to measure to get the correct clip.

 

[QUOTE=Sleazy Rider;1591721355]Thank you! I mentioned that in my quote. Your re-quote.
Also mentioned to measure his axle channel.

 

Ok. Thanks for the help.

I have a set of digital calipers. Just to clarify it, do I try to find hardened clips that are the same thickness as the groove? I will measure the diameter, which I hope works out to be a standard clip diameter. I imagine that you don't want the clip too tight or loose at all.

But I can't tell if I'll have room for one the same width as the axle groove. I've checked online all over and can't find anything to verify exactly what I need. I've read about various thicknesses but the issue is ambiguous. Furthermore, I called a local shop who "specializes" in Corvettes. Their mechanic told me to just get standard clips and double them up if needed. It doesn't sound right to me.

Any thoughts???

 

Here you go. Excellent deal!!
http://www.coreswest.com/snap-rings/

 

Hey! AWESOME!!

You are the coolest. Thank you.

 

Buy nothing except the "correct" retaining rings and I'd think you need at least new pinion washers. Tom's may have those also. Buy a clutch pack and finish the build after a very close inspection.

There's every reason to believe there's way more wrong with your build than you suspect, check the fit of the pinion shaft in the case for sure.

You're so concerned about fluid with "no concern" for cost but you're attempting to "short-cut" the hard parts. DUMB, FOOLISH, SILLY - call it what you like but makes no sense.

 

I did not see this addressed in anyone else's response: The snap ring you use determines the end play on the stub axles. You don't simply measure the groove in the axle and throw a clip in there to fit the groove. I would buy the kit, then you can set the end play correctly by selecting the correct thickness snap ring and not have to redo this sooner than later.

 

I'm not sure how you fabricated the idea that I'm attempting to short-cut anything. I discovered this by accident.

Initially, I didn't know that clips were supposed to hold the shafts in place. But after seeing the groove in the stub shaft, it seemed clear that something should go there. It caused an investigation of the differential online and eventually inside the case. I had no problems in the past without the clips installed although I can see that the seals leaked a tiny bit. And true, I am really not concerned at all about cost when I understand what the advantages are of spending more time and/or money.

At this point, I'm trying to get up to speed on all that needs to be done so I can get back to my initial project. That means understanding how to determine what could be worn and how to fix it. On inspection, nothing in the differential is chipped or scratched. Everything looks great. I'm investigating it all further to take care of whatever needs doing. Obviously something has gone on because I found the remnants of both clips inside. But I also recognize that I don't know what I don't know. That's why I inquired of you good people; to get objective help. That said, I most likely am a silly and dumb fool. It's nice of you to notice.

I'm working through as much of the parts order today. It's awkward finding everything... I keep seeing that Dodge Viper used a similar differential. Some of the parts turn up listings for both cars.

By the way, I've had an FSM set ordered from one of the forum vendors since last fall. It would be nice if it was sitting on my workbench already!

 

I believe it's important to know if this is thought to be an OE/GM build or maybe a D44 build by someone other than OE. I assume the differential is now out of the car. Correct?

On the bottom of the housing there should be four lines of information etched into the cover. The OE/GM build, the ratio and DANA information. Also on the ring gear should be all of the information that could be used to ID the rear.

What year is it thought to be? Post the info on the ring gear and also the bottom of the differential housing to determine if it's a match. What year is this car? Is the ZF and the D44 original to the car?

It's unusual to have both retainers fail, I've actually never disassembled one that had a single failure.

I'd say you need to confirm the clutch-pack assembly, do the pinion washers I mentioned, check the pin for fit to the case minimum.

It's maybe time to consider bearings (6), seals (3) minimum and reassembly properly. Some bearing kits are serviced only with a single spec retainer (2), some with an assortment and some with none. Much depends on where you shop.

A search from here for "D44 clutch pack"

will generate 50+ references to D44 builds. Some very good reads for you:

https://www.corvetteforum.com/forums...rchid=53646572

Sometimes the search input won't stick but if you do a search for the same you should end up with similar results.

*** Do all of your searches from here (C4, '84 - '96), use the "SEARCH THIS FORUM" button above the threads/posts columns and your results will cover all of the C4 sub-forums, perf, general etc.

https://www.corvetteforum.com/forums...-1984-1996-19/

 

That's great advice and information. I'll check to see if everything is original. The car has really low miles and was unmolested when I bought it several years ago. It was also un-maintained and apparently home to various vermin and farm animals. This is good to know. I appreciate the "plain English" to help me understand.

By the way, the differential is still in the car. All I've removed is the bat-wing cover and, of course, the half-shafts. I have the diff blocked up for support.

I'll report back what I find out. I hope its good.

 

Does anyone know a source for Dana 36 selective snap rings?

 

Did you check the link to CoresWest (see the post above)?

I've been working through my issue with the Dana 44. Amazingly, there isn't a single place I can find that has a complete offering of parts. I've had to order from five different suppliers to get the things I know I'll need. There will be more I'm sure.

Someone out there must be a one-stop-shop for this stuff, but I couldn't find it. I live in the Seattle, WA area and called every parts store I could think of. The 'Mom & Pops' were the most help. Chain stores were completely clueless.

I swear to this... I called a shop in Tacoma yesterday in search of stub shaft seals. A guy answered and I asked for someone in the parts department. He indignantly said, "You're on the phone with him."
I asked for stub shaft seals that go in the differential of a 1990 Corvette.
He said, "Okay. And these are for the front of the car, correct?"
It caught me off guard and then I said, "Seriously, Corvettes have never been front wheel drive."
In reply he asked, "So the shaft seals are in the rear then?".
I said, "Uh, yeah." I was stunned.
After a few seconds of thinking while his keyboard tapped in the background, he asked, "How many Danas does it have?"
I answered, "One...Dana... I guess I don't understand your question."
He said, "It can't be one. My computer says it could have either 36 or 44 of them."

I said, "I'm pretty sure I should keep calling around on these seals."

I called Yukon Gear and Axle and talked to a guy in the sales department. He was really helpful. It turns out they sell C-clips as well. I didn't realize it initially but they are here in Seattle. The number is 1-888-905-5044 use extension 5437. The seals are going to be delivered today UPS. $19 each. C-clips run about $8 each.

 

WOW.. if you only recorded the Conversion. this is why most people do there own work. The salesman's "Computer" TOLD him NO way. this is the kind of staff you can get at shops OR dealers. I hope it was the maintenance man. that picked up the phone after hours?? Nothing wrong with a maintenance position!!!! but UN-real??? I did already find you the Snap- rings.
http://www.coreswest.com/snap-rings/

I would really re-examine the diff. the Snap - rings are VERY strong. even with these . i did break a tip..

 

Yes. Thank you. I did follow the link you sent yesterday (very helpful) and got the snap rings ordered. I spoke with a salesman directly to verify that they were the right ones. He checked their order history. They had been ordered over and over for Corvette. He also stated that the Dana 44HD is the same as used in Dodge Viper. AND he said it's a very robust differential. It pleases me to know that there are portions of my car that aren't fragile.

Actually, I can't knock my '90 Vette. It's getting to be a pretty old car (although very low mileage) and is still great. Overall things have held up quite well. I'm sure if it had been maintained as it should, it would even be better.

As for the parts stores, you are right. Its a real problem when people can't do anything without being told what to do by the "magic box". I grew up in a small town with a local speed shop of sorts. Everyone who worked on cars shopped there. The owner, Kelly, knew so much about so many things. And he knew who to call if he didn't know. I restored a late '40's Buick and he helped with every odd and outdated detail. He helped me with multiple muscle car restorations and would even stop by from time to time in case I needed straightening out. He retired and sold his shop to an Autozone about 15 years ago. I really miss that guy and his cluttered, oily store.