Dana 44 Diff Cover: Selection, Install & Reviews

Understanding the Dana 44 Differential Cover

The Dana 44 differential is a popular axle used in a variety of vehicles, especially Jeeps and light trucks. The differential cover protects the internal gears and components of the differential from damage and contamination. Upgrading or replacing the diff cover is a common modification for off-road enthusiasts and those seeking improved performance or durability.

What is a Differential Cover?

The differential cover is a metal plate that bolts onto the differential housing. It seals the differential, keeping the gear oil inside and preventing dirt, water, and debris from entering. The cover also plays a role in the structural integrity of the axle assembly.

Why Upgrade Your Dana 44 Diff Cover?

• Protection: A stronger diff cover can better protect the delicate gears inside the differential from rocks, impacts, and other off-road hazards.
• Durability: Thicker materials and reinforced designs can withstand more abuse and prevent the cover from bending or cracking.
• Cooling: Some aftermarket covers feature cooling fins or increased fluid capacity to help dissipate heat and improve differential performance.
• Oil Capacity: Upgraded covers may increase the oil capacity, providing better lubrication and cooling for the gears.
• Appearance: A new diff cover can add a custom look to your vehicle.

Types of Dana 44 Diff Covers

There are several types of Dana 44 diff covers available, each with its own advantages and disadvantages.

1. Stock Replacement Covers

• These covers are direct replacements for the factory cover and are typically made from stamped steel.
• They offer basic protection and are the most affordable option.
• However, they are not as strong as aftermarket covers and may be prone to damage in off-road conditions.

2. Heavy-Duty Steel Covers

• These covers are made from thicker steel than stock covers and offer improved strength and durability.
• They are a good option for those who want more protection without the added cost of a high-end cover.

3. Cast Iron Covers

• Cast iron covers are very strong and resistant to damage.
• They also offer excellent heat dissipation, which can help to keep the differential cool.
• However, they are heavier than steel covers and may be more prone to cracking under extreme impacts.

4. Aluminum Covers

• Aluminum covers are lightweight and offer good heat dissipation.
• They are also resistant to corrosion.
• However, they are not as strong as steel or cast iron covers and may be more expensive.

5. Fabricated Steel Covers

• These covers are made from welded steel plates and offer excellent strength and durability.
• They can be custom-designed to fit specific applications and offer maximum protection.
• However, they are typically the most expensive option.

How to Choose the Right Dana 44 Diff Cover

Choosing the right Dana 44 diff cover depends on your needs and budget. Consider the following factors when making your decision:

1. Intended Use

• If you primarily drive on the street, a heavy-duty steel cover may be sufficient.
• If you frequently off-road, a cast iron or fabricated steel cover may be a better choice.

2. Budget

• Stock replacement covers are the most affordable option.
• Heavy-duty steel and cast iron covers are mid-range in price.
• Aluminum and fabricated steel covers are the most expensive.

3. Material

• Steel is a good all-around material that offers a balance of strength, durability, and cost.
• Cast iron is very strong and offers excellent heat dissipation.
• Aluminum is lightweight and offers good heat dissipation but is not as strong as steel or cast iron.

4. Thickness

• Thicker covers offer more protection.
• Look for covers that are at least 1/4 inch thick.

5. Design

• Some covers feature cooling fins or increased fluid capacity.
• Others have a low-profile design to improve ground clearance.

Installation of a Dana 44 Diff Cover

Installing a Dana 44 diff cover is a relatively simple process that can be done at home with basic tools. However, it is important to follow the instructions carefully to avoid damaging the differential.

Tools You'll Need

• Wrench or socket set
• Torque wrench
• Drain pan
• Scraper
• RTV sealant or gasket
• Gear oil

Step-by-Step Instructions

1. Drain the gear oil: Place a drain pan under the differential and remove the fill plug. Then, remove the bolts holding the diff cover in place, leaving one or two bolts loosely attached at the top. Gently tap the cover with a rubber mallet to break the seal, and allow the oil to drain completely.
2. Remove the old cover: Once the oil is drained, remove the remaining bolts and carefully pry the old cover off. Be careful not to damage the differential housing.
3. Clean the mating surfaces: Use a scraper to remove any old sealant or gasket material from the differential housing and the new diff cover. Clean the surfaces with a solvent to ensure a good seal.
4. Apply sealant or install a gasket: Apply a thin bead of RTV sealant to the mating surface of the differential housing, or install a new gasket. Follow the manufacturer's instructions for the sealant or gasket.
5. Install the new cover: Carefully position the new diff cover over the differential housing and align the bolt holes. Install the bolts and tighten them to the manufacturer's specifications using a torque wrench.
6. Fill the differential with gear oil: Remove the fill plug and add gear oil until it reaches the bottom of the fill hole. Refer to your vehicle's service manual for the correct type and amount of gear oil.
7. Replace the fill plug: Install the fill plug and tighten it to the manufacturer's specifications.

Dana 44 Diff Cover Reviews and Recommendations

Here are some popular Dana 44 diff cover brands and models to consider:

• Artec Industries: Known for their heavy-duty, fabricated steel covers.
• Yukon Gear & Axle: Offers a variety of covers, including steel and cast iron options.
• Mag-Hytec: Specializes in high-capacity aluminum covers with cooling fins.
• Poison Spyder Customs: Produces durable, fabricated steel covers with a distinctive design.
• Rock Hard 4x4: Offers heavy-duty steel covers with a lifetime warranty.

Frequently Asked Questions (FAQ)

1. What is the Dana 44?

The Dana 44 is a widely used axle manufactured by Dana Holding Corporation. It's commonly found in both front and rear applications in various vehicles, including Jeeps, trucks, and SUVs. It's known for its good balance of strength and weight, making it a popular choice for both on-road and off-road use. — Jets Game Today: What Channel Is It On?

2. How do I know if I have a Dana 44 axle?

The easiest way to identify a Dana 44 is by the shape of the differential housing and the bolt pattern on the cover. Dana 44 axles typically have a rounded or oval-shaped housing. You can also check your vehicle's service manual or look for a bill of materials (BOM) tag on the axle itself.

3. What is the purpose of a differential cover?

The differential cover serves several crucial purposes: it protects the internal gears and components of the differential from damage from rocks, debris, and other hazards, it seals the differential housing to prevent gear oil leaks, and it helps maintain the structural integrity of the axle assembly. — Apple Event Live Blog: Updates, News, And Announcements!

4. How often should I change my differential fluid?

The recommended interval for changing differential fluid varies depending on your driving conditions. Generally, it's a good practice to change the fluid every 30,000 to 50,000 miles, or more frequently if you do a lot of off-roading or heavy towing. Refer to your vehicle's service manual for specific recommendations.

5. Can I use a different type of gear oil than what is recommended?

It's crucial to use the gear oil type specified in your vehicle's service manual. Using the wrong type of oil can lead to premature wear and damage to the differential components. If you're unsure, consult with a qualified mechanic.

6. What are the benefits of using an aftermarket diff cover?

Aftermarket diff covers offer several benefits, including increased strength and durability, improved protection for the differential gears, enhanced cooling capabilities, and increased oil capacity. They can also add a custom look to your vehicle.

7. How do I choose the right Dana 44 diff cover for my vehicle?

Consider your intended use, budget, the material of the cover, its thickness, and any special design features. If you primarily drive on the street, a heavy-duty steel cover may be sufficient. For frequent off-roading, a cast iron or fabricated steel cover is recommended.

Conclusion

Upgrading your Dana 44 diff cover is a worthwhile investment for protecting your differential and improving your vehicle's performance. By choosing the right cover and installing it properly, you can ensure the longevity and reliability of your axle assembly. — Naz Reid Vs. OKC Thunder: A Detailed NBA Analysis