subroc

iTrader: (2)

I'm getting ready to put my Dana 44 in the car and so far it's taken 3 quarts of gear oil and is still not up to the fill hole. Should I keep going or have I already put too much in? That just seems like a lot to me. My old 9 bolt with a t/a cover took just barely 2 quarts.

skinny z

IIRC my rebuilder added a pipe plug just below the fill hole on my D44 TA cover so as to limit the amount of fluid added. I can't say exactly the amount needed to fill although I'm certain that using the cover as a reference added too much fluid. As a guide, the axle tubes need some fluid in them but not so much as to keep the bearings and seals covered in oil.
I could qualify this if I was able to check out the cover however I'm away from my shop for the next few days.
Maybe this bump in your thread will solicit other replies.

subroc

iTrader: (2)

Yea I thought it seemed high. I just drained half a quart out and called it good at 2.5. No weird noises.

skinny z

I checked a couple of websites and the Jeep guys are saying about a 2 quart capacity.
When I was filling mine to the fill hole on the TA cover, it was about 4 quarts. I was getting a lot of fluid coming out the vent tube when the diff was fully warmed up but I had no idea why. It was the rebuilder at the 4 x 4 shop who filled me in (and added the "sight" plug).
.

midias

I am not sure if the dana is the same but on the 10 bolt with the TA cover you open the factory fill hole but fill through the cover until it comes out the factory hole. If you try to fill until it comes out the cover hole it can take a ton. Usually the cover adds about an extra 1/2 quart.

subroc

iTrader: (2)

The factory fill hole on the Dana was on the old cover. It was a good deal lower down on the cover than the t/a cover.

skinny z

Now we know.
I'll get a picture of my modified cover once I'm home again. I'm thinking it's a full inch lower than the fill hole. It more or less lines up with the bottom of the axle tubes.