Mini buggy front diff

[kevin quesenberry]

CJDave, are the side gears and internals the same as the 8.8 out of a mustang? I used to play with them a little, may have some stuff.

[Wayneski]

Just saw this thread. I guess I have the same problem/want in lightweight front diff for a buggy.

I am building a light weight off-road 4WD buggy using a VW Syncro transaxle for the rear diff, powered by a Suzuki SV1000 motorcyle engine and 6 speed transmission so 30 forward speeds, 6 reverse! The Syncro diff (with locker no less!) is set at 4.86. I do not want to use the VW front diff, it's over 100 lbs!

Can you suggest a small light weight front differential for independent front suspension that uses CV joints on each side which has 4.88 gearing (or 4.88 ratio is available for it as an after market item)? It does not need to have a limited slip or diff lock of any kind although for the future, that would be great. I'm hoping to find something with a form factor like the Ecclipse differential, its only 7" wide from CV to CV.

Jeremy at Just Differentials suggested using the Dana35 IFS TTB diff with CVs; all the good stuff is available for that diff, ratios, lockers, etc. Apparently Ford Explorer went to CVs in 1995 and some others did later. However when I found one, the one I saw had that big elephant nose axle tube sticking out the side.

So CJDave, short of finding a narrow STOCK IFS diff, how realistic do you think it is to do what you said, chop off the end(s), install whatever's needed (bearings, seal) and marry those axles to a CV flange, either VW Type II or 930 (I'd prob rather go with Type II, they are smaller)? But first tell me, if it did work, how wide would it end up being, approximately, flange to flange.

Any help would be appreciated. Thank you.
Tim, Denver and San Diego, 303-861-2442

[cjdave]

Originally Posted by kevin quesenberry

CJDave, are the side gears and internals the same as the 8.8 out of a mustang? I used to play with them a little, may have some stuff.

Most 8.8 stuff is the same. so side gears should interchange as long as the donor is the same type differential (open vs posi)

[cjdave]

Originally Posted by Wayneski

Just saw this thread. I guess I have the same problem/want in lightweight front diff for a buggy.

I am building a light weight off-road 4WD buggy using a VW Syncro transaxle for the rear diff, powered by a Suzuki SV1000 motorcyle engine and 6 speed transmission so 30 forward speeds, 6 reverse! The Syncro diff (with locker no less!) is set at 4.86. I do not want to use the VW front diff, it's over 100 lbs!

Can you suggest a small light weight front differential for independent front suspension that uses CV joints on each side which has 4.88 gearing (or 4.88 ratio is available for it as an after market item)? It does not need to have a limited slip or diff lock of any kind although for the future, that would be great. I'm hoping to find something with a form factor like the Ecclipse differential, its only 7" wide from CV to CV.

Jeremy at Just Differentials suggested using the Dana35 IFS TTB diff with CVs; all the good stuff is available for that diff, ratios, lockers, etc. Apparently Ford Explorer went to CVs in 1995 and some others did later. However when I found one, the one I saw had that big elephant nose axle tube sticking out the side.

So CJDave, short of finding a narrow STOCK IFS diff, how realistic do you think it is to do what you said, chop off the end(s), install whatever's needed (bearings, seal) and marry those axles to a CV flange, either VW Type II or 930 (I'd prob rather go with Type II, they are smaller)? But first tell me, if it did work, how wide would it end up being, approximately, flange to flange.

Any help would be appreciated. Thank you.
Tim, Denver and San Diego, 303-861-2442

That is the big problem with most suv front differentials. the factory off set the differential to clear the oil pan on the engine. When they did this they put a axle tube of some sort in one side to keep the cv shafts the same lenth.
I don't have a dimension for you on how narrow a modified non independent differential would be, but It is on my list of things to work on so I should have a answer to that question in the next week or so.
I know everyone would like as narrow as they can get so do I so that will be part of the focus on the design side of this.

[Little Bandit]

What sort of angle to the stock CV's get for these IFS differentials? Is it worthwhile to stick with the stock CV shafts?

[Wayneski]

CJDave:

If you/we could figure this modification out, I think it would be a sought after item, especially on a fairly lightweight but durable unit (Dana 35?) which has the versatility of all the good inards at reasonable cost.

Since I don't have one here, does anyone have pictures or know where to get a shop drawing of the this IFS front diff. I'd like to figure out what would be needed to make it work: addition bearings, seals, etc.

Also if you have one (even with the tubes still on it) you might weigh it and let me know how heavy this unit is.

Thanks
Tim