Dana 44 TTB Long-Travel System Custom 4.5 plated

Giant Motorsports Dana 44 TTB Long-Travel System

Engineered for Strength. Built for Speed. Proven in the Desert.

Our Dana 44 TTB beams are engineered for extreme off-road performance, offering increased strength, optimized geometry, and maximum wheel travel for high-speed desert use.

Beam Construction & Design

• 4.5” per side extended track width
• Constructed from:
  • 1/4” main plates
  • 3/16” boxed sections
  • 1/8” overlay plating
• Machined billet beam ends designed to retain the factory-style spindle
• Fully CAD-designed and fully plated — top, bottom, front, and rear
• Driver-side beam includes an integrated truss with raised fill plug for added strength and serviceability
• Additional rear beam gusseting reinforces known Dana 44 weak points
• Designed with a 4” lift geometry to maintain proper camber throughout suspension travel

The beam containing the third member features a replaceable 1/4” thick bash/skid plate to protect the housing while allowing easy serviceability.

Suspension Geometry & Performance

These beams are designed specifically for coilover shock setups and wider fiberglass fenders, allowing for increased suspension travel and tire clearance.

Our high-clearance radius arms are engineered with added caster for:

• Improved straight-line stability
• Better steering return
• Increased control during high-speed cornering

Radius arm components include:

• 1.25” heims
• Spacers
• Jam nuts
• Bolt-on pivot boxes

Axles & Components

• Forged, double heat-treated 4340 Chromoly axles
• Aircraft-grade material for maximum durability
• Includes long and short extended axles
• Outer U-joints not included and must be added separately

Wheel Travel Capability

Depending on shock length and mounting configuration, this system is capable of 18–20 inches of wheel travel.

No core charge required — all components are fully fabricated and do not rely on modified factory parts.

Included Components

• 4.5” Extended Dana 44 TTB Beams
• Bolt-on bash/skid plate
• 1” uniball with C-clip and machined misalignments
• Radius arms with heims, spacers, jam nuts, and pivot boxes
• 4340 Chromoly long & short axle shafts

Engineering the Edge — The Giant Motorsports Process

Precision Benchmarking

Development begins with full 3D scanning of OEM Dana 44 beams and differential housings. This allows us to map factory geometry, identify structural limitations, and engineer solutions that retain proper alignment while dramatically increasing performance.

Wider Track, Greater Control

By increasing track width, we improve leverage ratios and vehicle stability. The result is enhanced control through high-speed terrain, deep whoops, and aggressive cornering.

Material Science & CNC Precision

• Constructed from premium HR P&O (Hot Rolled Pickled & Oiled) steel
• Strategic multi-thickness design:
  • 1/4” reinforcement in high-stress zones
  • 3/16” and 1/8” sections for optimized weight savings
• CNC laser-cut and CNC-formed components for absolute precision

Every tab, gusset, and joint is engineered to interlock perfectly, ensuring consistency, strength, and repeatable fitment.

The Giant Standard

The result is a fully fabricated, race-ready TTB system designed for serious off-road performance. Built in-house, tested in real-world conditions, and engineered for drivers who demand durability, control, and confidence at speed.

This is not a modified factory beam.
This is the evolution of the Dana 44.