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Old 09-03-2014, 03:16 PM   #1 (permalink)
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Tight fitting Dana 44 armored cover

Anyone have firsthand experience on which Dana 44 high pinion HD welded covers fits closest to the ring gear? I'm putting together a '77 F150 Dana 44 axle and '78 F250 outers. My F250 tie rod already has a bump out to clear the factory stamped cover. I can't seem to find and concrete info online about dimensions nor can I get any answers from the "customer support" at the mfrs. The only thing I can find touting any sort of custom fit is Ballistic Fabs cover for the JK Rubi. Jeep Rubicon Dana 44 Differential Cover I called them and still nothing more than "I think it will have the same diff flange as a Ford 44, you can send it back if it doesn't fit".
So what have the rest of you found regarding a HD Dana 44 cover that clears the tierod in the stock location? Luckily the F250 knuckles mount the tierod quite a bit higher than any other knuckles I've seen so it does help by nit being in exactly the widest part of the cover.
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Old 09-03-2014, 03:23 PM   #2 (permalink)
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Not a welded cover, but the ARB cover is very close fitting. Another option would be the Warn skid, which goes over your stock cover, but stops short of the tie-rod.
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Old 09-03-2014, 05:03 PM   #3 (permalink)
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The ARB just isn't for me. I've seen the 1/2 guards that go over the lower part of the stock cover however I live on the gulfcoast and lapped steel just loves to collect salty dust/moisture and rust out. With all the nasty home grown fab I'm doing on my build the welded diff covers will "fit" the theme.
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Old 09-03-2014, 05:05 PM   #4 (permalink)
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The Barnett uses a stock cover. You can't get any better clearance.

Dana 44 Heavy Duty Differential Covers [BP-DT044] - $114.00 : Barnett Performance Products, Race Tested and Rock Garden Proven

Here's one on my 60.

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Old 09-03-2014, 08:07 PM   #5 (permalink)
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The Barnett would be very good, however I'm not too keen about the 1/8" steel they use for the shell. I don't intend to go round bashing my axle on tree stumps and boulders but other than the double wall nature of Barnetts' cover I'd just as soon find a factory HD cover for the $$$
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Old 10-12-2014, 08:37 PM   #6 (permalink)
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This is the one I bought. If you need a tight fit to the ring gear, this is NOT the one to get!! It has a ton of space between the gear and the cover. I'll try to get a measurement tomorrow.
Rubi 44 from Ballistic



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Old 10-26-2014, 09:09 AM   #7 (permalink)
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Here's the differences between the Rubi 44 cover from Ballistic vs the stock stamped version with a typical paper type gasket.

Stock cover to ring gear is around .6"
Ballistic cover to cover is around .685"

I used Play-Do and calipers to determine this You can see the clean spot on the ring gear where the Play-do touched and removed the lube I'd sprayed on the diff to keep it from rusting while deciding on a cover.








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