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MODIFYING YOUR DANA 44 DIFF COVER
DANA 44 FRONT AXLE TECH
One of the first things you can do to add some protection to your front Dana 44 is get a factory 'thick' cover. They are at least twice as thick as the thin covers. And if you find one at the junk yard or in your parts pile they are almost free!
Factory thin cover.
Factory thick cover.
Another almost free modification for an axle that has the pinion rotated way 'up' is to move the fill hole location to increase the fluid capacity. If you use a hole saw you can cut the factory fill plug out then cut a new hole and weld the slug that you cut out into the original hole and put the fill plug into the new higher hole. Just weld on both the inside and out to make sure it is 100% sealed.
Original fill plug location.
Higher fill plug location.