Put a drain in your D44

[Hib Halverson]

A number of years ago, I was conversing with Marc Haibeck about ZR1 drive axle service and he told me he'd figured out a way to put a drain plug in a Dana 44. Those who've ever had to suck stinky old gear lube out of a ZR1 rear axle know how much nicer it would have been had Dana put drains in their axles.

Anyway, I followed Mark's procedure and installed a plug in my D44. Ever since then, changing axle lube is as easy as unscrewing the drain plug, waiting for the fluid to drain dry, replacing the drain plug, then refilling the axle.

A week or so ago, I tried to find those old notes Marc gave me and could not so I emailed and asked him again.

So, just in case, Marc's procedure has not been discussed recently, I'll post it here. Mark said...

The center of the plug hole is in the cover, 1 3/8" left (drivers side) of the center cover bolt. Then 3/4" up from the lower edge of the cover. The hole will enter the case just above the lowest part of the case floor. We use a 1/4" NPT plug.

If you drill the hole when you need to change the fluid, do it with the axle full of lube and, when you drill through the cover wall, the resulting initial rush of fluid will wash any chips or other drilling debris away.

If you're really good, you'll be ready with your 1/4-pipe tap. As soon as the drill comes out, stick the tap in there and cut the threads. Screw the tap out of the hole then let what's left of the lube drain out and wash away the chips from the thread cutting.

Install your pipe plug, then refill the axle with the GL5 gear lube of your choice.

Thanks to Marc Haibeck for figuring out the drain plug installation.

[tf95ZR1]

Pic?

[Dynomite]

This may help.....a bit different version of the same modification

See item #4 LT5 Added Systems

[tf95ZR1]

Originally Posted by Dynomite

This may help.....a bit different version of the same modification

See item #4 LT5 Added Systems

Thanks, Dyno. Very helpful.
PS: I just re-read some of your tech info- INVALUABLE! Thanks!

[mgbrv8]

I came up with this last year its the least intrusive way I could think of ( post #10-11)

http://www.zr1.net/forum/showthread.php?p=74800

Dave H

[Hib Halverson]

Originally Posted by tf95ZR1

Pic?

Ah, well...the car's at my storage garage for a while. I won't have it back here for several weeks, but, if no one else has posted an image by then, I'll shoot one and post it.

[vilant]

Originally Posted by mgbrv8

I came up with this last year its the least intrusive way I could think of ( post #10-11)

http://www.zr1.net/forum/showthread.php?p=74800

Dave H

Seen this post before. Thought it was pretty cool way to drain the fluid. No drain plug needed and you can't tell its been modified.

[Hib Halverson]

Originally Posted by vilant

Seen this post before. Thought it was pretty cool way to drain the fluid. No drain plug needed and you can't tell its been modified.

Pretty cool way to do it, no doubt but...you have to remove the axle and completely disassemble it to perform the mod. On the other hand, those preparing C4 ZR1s for NCRS and so forth ought to take note.

For others, admittedly, you're left with a visible drain plug, but the Marc's idea is easier and far more practical.

[vilant]

Originally Posted by Hib Halverson

Pretty cool way to do it, no doubt but...you have to remove the axle and completely disassemble it to perform the mod. On the other hand, those preparing C4 ZR1s for NCRS and so forth ought to take note.

For others, admittedly, you're left with a visible drain plug, but the Marc's idea is easier and far more practical.

True. I wonder if there's way to get a 90* drill in there, or a Dremel w/ a flexible attachment. Probably not enough room though, with the gears in place.

[scottfab]

Originally Posted by mgbrv8

I came up with this last year its the least intrusive way I could think of ( post #10-11)

http://www.zr1.net/forum/showthread.php?p=74800

Dave H

Excellent............... doing it with a slight variation of a hole
on both sides of the hump.