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.