Interested in hearing some opinions or thoughts on running aftermarket diff covers on the Dana 44 or any axle. I hear conflicting Opinions of people saying while you gain protection with the beefier covers you lose some heat exchange-therefore your diff will run hotter. This is vice-Vera for aluminum diff-covers according to what I’ve read.
Aftermarket Differential Covers
- Thread starter Michaelp3257
- Start date
Are you hitting your stock covers on rocks? If not, leave them alone.
I'm not sure heat is where the discussions of diff covers should be focused.
Depends on what type of differential cover you use. Some, like the Dana Spicer ones will perform very similar to OEM, while others significantly change how the lubricant flows. Personally I would stick with the Spicer style covers that are similar to stock, just thicker
Also you'll need to watch trackbar and steering clearances
Also you'll need to watch trackbar and steering clearances
Gale Banks did an excellent Utube video on how (some) aftermarket dif covers affect the flow of lubrication inside the housing. It is pretty dramatic how a cover can cause the oil to stop lubricating certain areas (not his tho) especially the front pinion bearing. If nothing else it is entertaining.
It was a good series, though did he address a problem that we see often? If I recall, the diff covers that seemed to do the worst in his tests are not the kinds of covers we see on a TJ where big boxy covers already don't fit.
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Pretty much all of this. I have lots of respect for Mr. Banks. His testing was thoughtful, insightful, and well done with lots of diligence and effort. I do not however see that he solved a problem that needed solving for what we do and use our diff covers for. Not only that but if the oiling being other than stock routing as dictated by the internal shape of the cover was an issue that contributed to any untoward wear or other issues, it would certainly show up on the TJ. That would be due to high numbers of aftermarket covers, larger tires adding load and the work we ask them to do. I think generally he gave us an answer to a question that wasn't asked.
X2 to this.
And X2 to this as well. This is why I think a lot of people like the Currie / Barnett covers. It's a stock cover with a reinforced lower portion.
For those who want more shovel on their TJ, here's the result of the Banks testing. It's enormous.
I run an ARB rear diff cover and an early 2000’s Dodge front cover with a Warn lower diff guard.
The only reason for the ARB is because I picked up a pair of brand new covers stupid cheap as part of a bundle deal a couple of years ago.
After peeling the front cover open on my one month old 2003 Rubicon I’ll never run without lower protection of some kind. I also took a grinder and smoothed out the lower portion of the covers that hung down ever so slightly past the diff itself.
The only reason for the ARB is because I picked up a pair of brand new covers stupid cheap as part of a bundle deal a couple of years ago.
After peeling the front cover open on my one month old 2003 Rubicon I’ll never run without lower protection of some kind. I also took a grinder and smoothed out the lower portion of the covers that hung down ever so slightly past the diff itself.
So, would the ARB diff covers be considered ok? They're really the only ones I've looked at. I would think with the ARB R&D budget, they probably put some thought in to it.
Have I ever dented a diff cover bad enough that It touched ring or leaked? No.
However, I do really like the drain/fill aspect, and the dip stick for inspecting, magnets, etc.
And, yes, the bling factor is appealing in that area as well. I also would appreciate the added protection in an area that, while I may never hit it, my driving skills are what will determine how important it ends up being lol
Have I ever dented a diff cover bad enough that It touched ring or leaked? No.
However, I do really like the drain/fill aspect, and the dip stick for inspecting, magnets, etc.
And, yes, the bling factor is appealing in that area as well. I also would appreciate the added protection in an area that, while I may never hit it, my driving skills are what will determine how important it ends up being lol
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I throw it out there on most diff cover threads but alloy has a stock-shaped cover that is (what we believe and determined by a team of scientists that @jodomcfrodo knows) stamped steel and is 5/16" thick. $50 too, much cheaper than the $200 barnett/currie versions.
I think the consensus was that the cover is cast from a stamped mold (or something like that, not my expertise). My team of scientists was just a bunch of machinists I know. It has physical attributes of being cast and the shape of being stamped. Hopefully that makes some sort of sense because I don’t really know much about machining / manufacturing.
It is pretty beefy. I think I’d have trouble denting it no matter what process made it.
I am in the rocks a LOT so I switched mine out for Riddler Covers F&R, so far no issues at all other than some scratches.
89grand
TJ Addict
I have a Riddler front cover because my stock cover was dented and leaking. I don't flex the crap out of my Jeep, so if it has clearance issues, I have experienced it yet.
So, not knowing what the inside of my Dana 44 looked like or the condition of the lubricant I purchased a diff cover from amazon that looks identical to an ARB but has 4x4 embossed where the ARB lettering is.
Question: does this type of cover require more or less lubricant than the stock stamped sheet metal cover?
I removed my stock cover as todays project and the lubricant was pretty much all there based on what drained out. Didn't smell funny or burnt and looked like used oil. Installed the new diff cover and am now waiting the required time for the sealant to cure before re-filling the diff, basically sometime tomorrow. And yes, I do have 4 oz. of Mopar friction modifier to add.
Question: does this type of cover require more or less lubricant than the stock stamped sheet metal cover?
I removed my stock cover as todays project and the lubricant was pretty much all there based on what drained out. Didn't smell funny or burnt and looked like used oil. Installed the new diff cover and am now waiting the required time for the sealant to cure before re-filling the diff, basically sometime tomorrow. And yes, I do have 4 oz. of Mopar friction modifier to add.
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