Upgraded Dana 44 covers

[Kenneth G Zinis]

Hey guys,

Looking for upgraded Dana 44 diff covers, lots of big rocks around here. Have '03 Rubi. Will covers from any Dana 44 fit or must they be model/brand/yr specific?

Thanks,

Ken

 

[tworley]

Any 44 cover will fit. I am using one from an early 00's ram 1500 that is 3/16". Though one of the better covers out there is the barnett/currie. Stock is drying up and they're not exactly cheap.

https://tandjperformance.com/product/part-bp-dt044/

 

[Kenneth G Zinis]

Any 44 cover will fit. I am using one from an early 00's ram 1500 that is 3/16". Though one of the better covers out there is the barnett/currie. Stock is drying up and they're not exactly cheap.

https://tandjperformance.com/product/part-bp-dt044/

Thanks Tworely. I see some, including used ones, like ARBs and PSs around.

 

[tworley]

Thanks Tworely. I see some, including used ones, like ARBs and PSs around.

ARB is probably the worst. Its a flashy and attractive cover but the bulkiness of it will interfere with your trackbar and limit travel. PS is another popular one, and I had no trouble with it on 4" of lift and 2" bumpstops (couldve had less). The Currie/Barnett is all function, fashion for it was thrown out the window, but it does its job well and works with stronger steering and aftermarket trackbars

 

[jboswell11]

I went with the tera covers F/R on mine... based on the recommendation of Mr Blaine in this post (question asked about a dana 35 but the topic switches to Dana 44 covers some as well)

https://wranglertjforum.com/threads/recommendations-for-a-better-diff-cover.23839/

 

[Kenneth G Zinis]

ARB is probably the worst. Its a flashy and attractive cover but the bulkiness of it will interfere with your trackbar and limit travel. PS is another popular one, and I had no trouble with it on 4" of lift and 2" bumpstops (couldve had less). The Currie/Barnett is all function, fashion for it was thrown out the window, but it does its job well and works with stronger steering and aftermarket trackbars

Great info, hadn't considered the interference points. I have 4" lift.

 

[Kenneth G Zinis]

ARB is probably the worst. Its a flashy and attractive cover but the bulkiness of it will interfere with your trackbar and limit travel. PS is another popular one, and I had no trouble with it on 4" of lift and 2" bumpstops (couldve had less). The Currie/Barnett is all function, fashion for it was thrown out the window, but it does its job well and works with stronger steering and aftermarket trackbars

How are Rancho covers?

 

[jjvw]

Great info, hadn't considered the interference points. I have 4" lift.

This is why it matters.

 

[Kenneth G Zinis]

This is why it matters.
View attachment 146595

Yikes, that's tight!

 

[tworley]

How are Rancho covers?

They look big and bulky too since they felt the need to project their name way out there. Ive never seen one in person though and dont know the measurements.

 

[Alex01]

Buy the barnett covers. They offer the best protection without compromising any room for the track bar. I've pounded mine in the rocks and they are holding up great. I'd also get a reusable lube locker. It's so much better than scraping away rtv each time you need to open up the diff.

 

[Steel City 06]

I chose to buy the Spicer covers.

Spicer 10023536 Differential Cover https://www.amazon.com/dp/B01MF6DOOD/?tag=wranglerorg-20

They are made by Spicer, so they fit without any issues. On the front I did have to grind a couple of ribs by about 1/8” to clear the tie rod at full lock, but I have the Savvy tie rod. A Currie tie rod or OEM or ZJ tie rod probably would clear with no grinding

 

[LONGJP2]

Or something like this.

 

[jjvw]

I chose to buy the Spicer covers.

Spicer 10023536 Differential Cover https://www.amazon.com/dp/B01MF6DOOD/?tag=wranglerorg-20

They are made by Spicer, so they fit without any issues. On the front I did have to grind a couple of ribs by about 1/8” to clear the tie rod at full lock, but I have the Savvy tie rod. A Currie tie rod or OEM or ZJ tie rod probably would clear with no grinding

What about track bar clearance? See my pic above.

 

[Steel City 06]

What about track bar clearance? See my pic above.

I have yet to actually cycle the suspension to full bump, but I suspect the trackbar may contact a rib at full bump when both sides are simultaneously compressed. However, the cover is the shape of a stock cover except thicker and with ribbing. So even if it does, the ribbing can easily be trimmed. Based on the clearances from last time I cycled the suspension, I expect to need to trim 1/4” or less off of one or two ribs at the top.

 

[Irun]

The Barnett cover is a good one, but one of the priciest. I picked up a used Warn lower half cover and have been using it for years with no major issues. I have damaged a couple of the Allen bolts though.

Edit: Good grief, I just saw how pricey a new Warn 1/2 cover is. Another alternative would be Rock Hard, at $70

https://www.northridge4x4.com/part/...MI45SNzO2h6AIVCxgMCh0e9QoaEAkYAyABEgLq6vD_BwE

 

[DuncLJ]

I have the Rock Hard Diff Guard. Plenty strong with no worries about clearance. Mine is a Dana 30, but the clearance is the same on a 44.

 

[Kenneth G Zinis]

I have the Rock Hard Diff Guard. Plenty strong with no worries about clearance. Mine is a Dana 30, but the clearance is the same on a 44.

View attachment 146619

Rock Hard looks like good option. Can you install without draining/breaking oil seal?

 

[Irun]

Rock Hard looks like good option. Can you install without draining/breaking oil seal?

No reason you couldn't. You don't have to remove the cover, only remove the bottom 5 bolts.

 

[Mr. Bills]

. . . Can you install [Rock Hard and similar diff guards] without draining/breaking oil seal?

The correct answer is "maybe."

I've tried with 3 diff covers of similar style on 3 different vehicles. I was successful in installing them without breaking the seal twice of the three times. I thought. One of the covers started weeping oil a few weeks later and I had to re-seal the cover.

My final score: 1 out of 3.