Best diff covers for clearance on Dana 44 axles?

[PStov98TJ]

Diff covers are an oft debated topic. I can tell you from personal experience that the basic rule is very simple. If you hit the diff area hard enough to need a bulletproof cover, you will have destroyed something else on the axle long before you need the cover.

Aside from what has already been said about using an OEM or Barnett diff cover, this was my other thought. Save your money and sleeve the axle tubes and/or get a truss. Save room, especially on the front diff cover. Big ones don't play nice with the track bar and sometimes like to get a little too close to the tie rod as well.

 

[Chris]

Yep, I wouldn't waste money on anything other than the Barnett cover.

 

[Jerry Bransford]

I just came across a brand-new $40 Barnett differential cover for a Dana 44 I'm picking up tomorrow. I don't think the guy knows what he has.

 

[Jerry Bransford]

I picked it up today. It turned out to be a brand-new never installed T&J differential cover, the brand that Barnett took over. I knew it was old because it still had the T&J business card in the box. $40, new-in-box complete with a gasket and all the bolts. The guy who sold it to me won it many years ago & never installed it since he has f/r ARB lockers.

I am so stoked, I don't often run across a deal like I just got. What's cool about the design is they left the top of the cover alone so it can't interfere with any of the steering components like the tie-rod.

P.S. Don't bother looking for Barnett's webpage right now, it has been taken over by a porn site.

 

[Chris]

Damn, you lucked out!

Barnett's website hasn't worked right in a long time.

 

[Stinger]

Jerry, I am puzzled. What is the fitment issue with the ARB lockers?

Nice find BTW

 

[Jerry Bransford]

I don't believe there is a fitment issue, I assume he just wants to run the bright red ARB covers since he has their lockers.

 

[Stinger]

Got it.

 

[Jorge Bolivar]

Just order my diff covers from Barnett Performance.

 

[Chris]

Just order my diff covers from Barnett Performance.
View attachment 19507

Well done! These are the best ones you can get in terms of clearance and protection!

 

[Jerry Bransford]

Just order my diff covers from Barnett Performance.
View attachment 19507

Great cover choice, and I'm glad to see their website is back up. The last time I was there it had been hijacked and was linking to porn sites.

 

[Rob5589]

Looks like a stock cover thats been modified??

 

[Chris]

Looks like a stock cover thats been modified??

Yes, that's what they are basically.

 

[Rob5589]

Great cover choice, and I'm glad to see their website is back up. The last time I was there it had been hijacked and was linking to porn sites.

Just tried that link, ended up with multiple pop ups and weird links and when I searched for their site, Google listed the site as hacked.

 

[Jerry Bransford]

Just tried that link, ended up with multiple pop ups and weird links and when I searched for their site, Google listed the site as hacked.

Wow, me too! It was fine earlier this morning and it's frigging hacked again?

 

[Fouledplugs]

$110! That price is outrageous for what you get.

Solid Axle Industries has superior build quality and reasonable prices. Lifetime guarantee on their covers. 64$ Plus it includes zinc plated hardware.

http://www.solidaxle.com/productcart/pc/viewPrd.asp?idproduct=33&idcategory=7

Clearance isn't an issue with this cover for my 06. Don't throw away your money on a modified OEM cover.

 

[Jerry Bransford]

$110! That price is outrageous for what you get.

Only when you don't understand its benefits. Plus its higher cost is because it's not just a piece of cast steel like Solid's is. The T&J/Barrett cover design requires skill and welding to build... they don't just pour steel into a mold and paint it.

That Barrett design, originally made by T&J, is a very popular diff cover for high-end builds, I've had a couple of them. I had the exact cover you're recommending but I'm no longer running one. Thick heavy covers reduce clearance in front of them and many builds won't tolerate any reduced clearance. Especially up front where thicker designs like from Solid commonly cause the tie rod to rub against it.

 

[Fouledplugs]

By the way if you are going to run that "awesome" Barnett modified OEM cover, be sure to follow their directions: Upon installation of this cover, before operating the vehicle, check the inside clearances of the oil filler plug to be certain that the plug does not contact with the inner differential carrier, case, locker unit, or ring gear. Use of a marking compound is recommended to accomplish the inspection. If the fill plug does come in contact with inner components of the differential, the inner portion of the plug must be slightly ground to eliminate any such contact. Failure to do so will result in driveline related damage.

 

[Fouledplugs]

Only when you don't understand its benefits. Plus its higher cost is because it's not just a piece of cast steel like Solid's is. The T&J/Barrett cover design requires skill and welding to build... they don't just pour steel into a mold and paint it.

That Barrett design, originally made by T&J, is a very popular diff cover for high-end builds, I've had a couple of them. I had the exact cover you're recommending but I'm no longer running one. Thick heavy covers reduce clearance in front of them and many builds won't tolerate any reduced clearance. Especially up front where thicker designs like from Solid commonly cause the tie rod to rub against it.

I had the Barnett as well and returned it like you did, the welds were compromised on my first ride with it.

At the very least I like the fact Solid doesn't jerk their customers around with inflated prices and has lifetime support on their products.

Furthermore, the fact that the fill plug on the Barnett will make contact with the carrier and require grinding is a little over the top for some new Jeep guys.

 

[StG58]

Only when you don't understand its benefits. That design, originally from T&J and now made by Barrett, is a very popular diff cover for high-end builds, I've had a couple of them. I had the exact cover you're recommending but I'm no longer running one. Thick heavy covers reduce clearance in front of them and many builds won't tolerate any reduced clearance.

This is ESPECIALLY IMPORTANT on low lift builds. Most, if not all, of the more expensive and "cooler" looking covers WILL contact your drag link or track bar and cause things to bend or break. It's something that you absolutely have to check for on, say, less than 2-1/2" of lift. Cycle the suspension and carefully look for interference. The Barnett cover and the stock Dana heavy duty cover are actually your best bet on low lift rigs.