Hello all,

I thought my cover was leaking again but it turns out to be a patch welded over the hole at the axle tube insert.


I compared this to another HP i have and no weld, just the pressed axle showing in the hole.

Any idea of why the gear oil is making passed the pressed axle tub, Could this be a sign of something worse? Obviously it was leaking enough for the PO to weld it closed.

Also, Is this the correct cover for a HP. seems very high and after the new cover gasket and fill I am leaking at the bearing seals too. I am sure i could use new seals but if I am over filling they will leak again.

 

Sort of found my answer already but i will leave the post up in case it helps someone else.

Apparently the tube has "walked" it way out of the center a little and this is the cause of the leak. The PO had the hole along with the tube welded in an attempt to fix it.

The correct method would be to press the tube back in completely before welding. I was told that it has the potential to crack the center if it walks out to far.

Just now it is a pain to cut the weld so it can pressed back in.

 

Can anyone confirm the distance from the perch to the edge of the center housing on the passenger side?
The welded axle that is leaking measures 15 3/16
The extra axle (un-welded original) I have measures 15 exact. Not sure if that is correct or if it also has walked a little.

My passenger side tire does stick out about an inch farther than the driver, and my shackle is bent a little to compensate.

 

I have never seen an axle shaft walk before. or ever heard of it.
Is this a common thing?

 

not common but it happens, especially with abuse and lifts/bigger tires. personally, i'd start looking for a new axle housing. it sounds like its been abused pretty good, and fixed not so good. that "patch" looks like an attempt at an extra plug weld. if you are planning on jumping it, wheeling hard etc you should probably truss it. D44s bend all the time in light jeeps, much less big *** trucks.

everything should swap right in, and its a good opportunity to rebuild the diff while you're at it.

cover looks wrong, Dana axles definitely don't like to be overfilled, and usually anything past the centerline of the axle shafts/differential is over. i think 1.8-2qts for a front 44, been a long time since i filled one.

 

Where the fill plug is on his cover looks like it is way to high and would way over fill it. Just to the bottom of the tubes or a little less is all I use. The gears pull the lube up and around and the axles pull it down to the wheel brg's.

 

not on a front diff...lube oil is only for the carrier and ring/pinion. the tubes in a front axle are dry (if the seals are good).

your cover is probably off a jeep or chevy front axle

 

You right. My bad. Was thinkin rear axle.
Sorry

 

Neither have I but the shop i was talking to this morning said that is what causes the leak?? I agree the fill looks high, but it my other HP i got from the pic&pull.

What is odd is I just bought this truck from the original owner with 60k miles on it. The only driving it got was in parades and casual around town. The lift was for show only.

I would be surprised if it saw a dirt road.

Might be able to measure their HP housing to the perch? Love to know if I am out an inch ??

 

Well, yours has leaf springs, my '77 has coils ..... but as far as I know housings were same length and so I just measured holding my tape end against the right side steering knuckle on the inside where it wraps around the right lower ball joint and measured exactly as near as I can tell .... 31 inches to the center of the right most of the three lower bolts in the differential cover.

My front differential is also a HP 44 and my fill plug is exactly like yours and in the same place.

 

That's an original diff cover and wow your truck is beautiful! You should just treat it to a front 60 and be done with it

 

That is a nice truck Chris. Real nice. Take good care of Her Bud.

 

I am always looking for HP60 near by.

 

Looks like I found a HP dana 60 from a 78. It is a few hours away but i think i am going to grab it for 800 complete.