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  1. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    How to Get Easy-to-Read Gear Patterns If you only pay attention to one thing in this lengthy thread, this is it. Get this part wrong, and you’ll be chasing your tail endlessly trying to figure out if your pinion depth is correct. This is the voice of experience speaking, so for the love of God...
  2. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Measuring Ring Gear Runout This one will be quick. Checking ring gear runout requires the same tools as above (dial indicator gauge), only instead of putting the plunger against the ring gear teeth, you’ll be placing it against the back side of the ring gear. There’s a small lip you are aiming...
  3. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Measuring and Adjusting Backlash Backlash is one of the many critical measurements that needs to be made when setting up a ring and pinion in a differential. Backlash is simply the amount of play between the gear teeth of the ring and pinion. During normal operation, the differential heats up...
  4. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    The Basic Gear Pattern Setup Process This is where the repetition starts. If you are lucky, you may only have to go through this a few times at most, but unfortunately, this is where experience matters. Had I known what I was doing, or more to the point, what I was looking at when it came to...
  5. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Clean Up and Preparing to Run Gear Patterns Next up: cleaning, organizing, and taking care of the one-time install items that are necessary when setting up a differential. Most of these don’t have to be done in any specific order, so don’t read too far in to how these are ordered. Step 1...
  6. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Tear Down I hope you like the smell of gear oil, because you’ll be smelling it for a while. Step 1. Drain the old oil. My differential mounting fixture design allowed me to clock the differential housing every 90 degrees, so I turned mine sideways and drained most of the oil by removing the...
  7. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Mounting Fixture So how in the hell do you hold the differential while you are wrenching (and banging) on it during a gear swap? I agonized over this question for days on end. Putting it on the floor certainly won’t work, and you sure as hell can’t leave it installed in the car since the frame...
  8. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Tools Below is a list of tools that are either optional, recommended, highly recommended, or required for this task (based on my personal experience). This won’t be absolutely everything, but it should include the bulk of things that some folks may not have in their tool box. These are in no...
  9. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Shims I ended up having to deal with 3 different sizes/types of shims during this rebuild: solid pinion spacer shims (not required if using a crush sleeve), pinion shims, and carrier shims. It’s pretty easy to tell each one apart: To reiterate, the purpose of each shim is as follows: 1...
  10. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Crush Sleeve vs. Solid Spacer The pinion gear has two tapered roller bearings (outer and inner) that oppose each other, holding the pinion gear stationary in the differential housing (front-to-back and side-to-side) while still allowing it to rotate. As stated above, tapered roller bearings...
  11. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Viper Differential Bearings There are 6 total bearings in the Viper’s differential that can be serviced – you’ll only be dealing with 4 of them. The 2 you will (likely) not be dealing with are the stub axle support bearings that are pressed into the sides of the case where the stub axles enter...
  12. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Viper Differential Rebuild Parts Below is a list of the parts I ordered/received for this rebuild. Most of these supplies came from Jon B, and some I sourced myself (I’ll note those when/where applicable). I’m sure I’ll forget something, so if it looks like something is missing, please ask...
  13. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Viper Differential Information The 2003-2017 (Gen 3, 4, & 5) Dodge Vipers use the same basic design for the rear differential. The design is based on a Dana Super 44 differential, also known as a Dana 44HD, and sometimes (but rarely) known as a Dana 226. What it is NOT is a standard Dana 44...
  14. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Warning This is a hugely time and resource intensive project. I lost count of the number of hours I spent swapping shims, painting gear teeth, reading patterns, and taking it all apart only to do it over again. And over. And over. This is a repetitive process, no two ways about it. I also spent...
  15. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Disclaimer Let’s get this out of the way: I’m not a mechanic. I have no formal training when it comes to working on cars. Full stop. I have been turning wrenches for ~20 years, and I’ve done many projects on all of my vehicles, including this one. Most of them I’d say have even been successful...
  16. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Background/Motivation First and foremost, this rebuild was not done out of necessity. I am fortunate to have two complete differentials in my possession – the one that originally came with my car with 3.07 gears and the stock GKN Visco Lok, and a fully assembled Gen 5 differential (w/ 3.55s and...
  17. Steve M

    Viper Dana Super 44 Rebuild (How-to) - Gen 3/4/5 (2003-2017)

    Introduction The 2-3 people that follow me on Instagram (@sidepipedsnake) have figured out that I’ve been busy lately rebuilding the differential in my ’08 Viper. There is nothing new about what I’m doing – as a matter of fact, Viper owner Bryan Cowger (a.k.a. @cowger) did exactly what I set out...
  18. Steve M

    New Gen IV owner - Looking for shop

    Jon doesn't opt for anything - tell him exactly what you want, and he'll do his best to accommodate. But he is at the mercy of his suppliers...if they don't have 275s, then you'll have to make do with something else. That said, your Gen 5 Sidewinder fronts are 0.5" wider than your OEM wheels...
  19. Steve M

    another Transmission noise thread.

    I'd say go with your gut.
  20. Steve M

    another Transmission noise thread.

    That doesn't sound like R888R whine to me. R888R whine generally doesn't show up until you get to around 100 MPH or so, and it is a very distinct sound...you can hear it at the end of one of my quarter mile passes here: https://www.youtube.com/watch?v=aFX4Q_C3WHc At normal cruising speeds like...
  21. Steve M

    2014 Gen 5 window and door panel

    Regulator issues are quite common. Start here: https://www.youtube.com/watch?v=Wo1CeFSjJH8
  22. Steve M

    DURA DRESSING - Tire Coating

    The other stuff I used I applied once and never applied it again, but I don't wash my car all that often, and usually only put ~1,000 miles on per year, so I'm probably not the best data point. But that's also why I chose it...for me, it is pretty much do it once and never again, or at least...
  23. Steve M

    Steering?

    Mine is not locked tight in place...it behaves like you describe yours.
  24. Steve M

    DURA DRESSING - Tire Coating

    Same stuff I ended up using on my Continentals. I've used a similar product in the past, and it held up great for years with my driving habits. As with anything, it's all about the prep work. Based on the short clip you posted on YouTube, you clearly understand this. The tires as shipped are...
  25. Steve M

    AMSOIL vs MOPAR (Transmission Fluid)

    Not what you asked for, but another data point until Dean chimes in. This was my 3-4 synchro and 3rd gear (OEM 2008 TR-6060): The clutch teeth on the 3rd gear and 3-4 synchro were rounded, and some of them were chipped. Both had to be replaced when John Donato went through my transmission...

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