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Dana 44, 10 Bolt, Top Fill, Patterned Fins, Differential Cover

PML Part Number 9516, DISCONTINUED

PML Dana Differential Cover   As-Cast Finish, click on image to view larger

Volume: about 0.25 qt. over stock

Dimensions: Click here for dimensions. Check shape, size, number of bolts, level check hole location, axle rotation, vent if any, and clearance.

This part has been discontinued.

This cover was installed on 1960s GM trucks, 1970s F250s and 1997 to 2001 Ram 1500 trucks as well as some Jeeps.

Because the Dana 44 differential has so many uses and variations, read this pdf file on PML Covers for Dana 44 differentials for more information on what to check before replacing your stock cover.

The Dana 44 differential is found on many vehicles beginning in the 1940´s and is still used today. For example, Jeep CJ 1941-1975 rear ends and Ford Bronco 1966-1979 front ends are typically Dana 44s. There are several versions of Dana 44 differentials so please check your vehicle carefully to verify shape, number of bolts, clearance, rotation, and level check hole location.

Be very careful! 2009 and newer Jeeps or GM front ends may have a vent. In 2009, Jeep changed the design of the rear axles and added a vent so this PML cover will not work on these newer models. The suspension can be very close to the stock cover so there may not be any space for a larger differential cover. Always check for clearance and fitment.

Using on Front End

If you are planning to use this on a front differential, be sure you have enough room in all positions. The steering linkage moves forward and backward (in addition to side to side) as you turn the steering wheel. Reference this cover's dimensions.

Drain Hole, Fill Hole, Level Check Hole

This cover has three holes. The bottom hole is a drain hole. The plug at the top is used to fill the differential. The one on the side is left open when filling to let you know when the differential is full. Once oil starts to drip out the side hole, it's full.

Comparing Dana 44 Covers

Be sure to compare the number of bolts, shape, level check hole location to your stock cover and check if you have clearance for a larger cover.

Graphic on the left compares Part Number 5055 and 6057 fill levels. Graphic on the right compares the capacity and fill levels of PML's Part Number 9516 top fill and PML's Part Number 5055 low front fill cover and the stock cover 42960-1 (used on Jeeps).

PML Dana 44 Front Fill Differential Covers, fill levels compared    PML Dana 44 covers capacity
Click on an image to view larger in a separate window or tab.

Here is a link to a Wrangler Forum discussion about fill levels.

PML Differential Cover Compared to Stock

PML Differential Cover Part Number 9516 height compared to stock  PML Differential Cover Part Number 9516, compared to stock
Click on image to view larger.

These images show this PML differential cover compared to the stock cover.

This image compares the depth of all three PML Dana 44 differential covers and the stock cover. Click on image to view larger in a new tab or window.
PML Dana 44 Differential Covers depth comparisons


This PML cover for the Dana 44 has been installed on a variety of vehicles: 1500 Dodge Rams, Ford F250 and F350 trucks, Chevy Blazers, Jeeps, and GMCs.

2009 Wrangler

Sway Bar On a Wrangler

Some vehicles have a sway bar ½–inch from the stock differential cover. Wrangler will need to be lifted or the sway bar moved or modified. Sway bar too close as is to accomodate a larger aftermarket rear end cover.

2008 Wrangler

MBRP installed this cover on the front end and rear end differentials of their custom Jeep 2008 JK Wrangler Rubicon. MBRP has lifted and modified this Rubicon. On a stock Jeep, the sway bar is likely to hit a deeper cover.

PML cover on front of a Wrangler   
Click on image to view larger.

For a larger picture, please click one of the above images. A separate window will open showing a bigger picture. (The larger pictures take a minute to display.)

PML Differential Cover Features:

  • Increased oil capacity for cooler temperatures
  • Sand-cast aluminum with raised fins
  • 3/16-inch thick wall construction to add strength to differential housing
  • 3/8-inch thick gasket flange will not bend when bolts are tightened
  • Machined gasket surface for a secure seal using RTV or factory reusable gasket
  • Oil changes without removing the cover
  • All hardware provided, including magnetic drain plug

Learn more about finishes and construction of PML parts.