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I had heard that some people were drilling a small hole on the inside of the case near the bottom cover bolt. Then when you remove the cover bolt it drains the diff. I don't know if that would case a weak area in the case or if it would leak, but it sounds like a good idea. Try it and we will both know if it works. :cheers:
I am in the process of swapping my gears and drilled out for a pipe plug this past weekend. I am putting together a procedure for anyone who wants to swap their own gears and I took lots of digital pictures. I drilled the hole as close to the low point as possible, but NOT below the ring gear. I will weld in the pipe plug this Sunday, and I can post pics once I finish welding it in.....
From: San Diego , CA Double Yellow DirtBags 1985..Z51..6-speed
Re: Dana 44 Drain Mod?? (RX7 KLR)
It seems like drilling into the lower bolt hole would make it very likely to leak from there. If I had mine out, I'd go ahead and tap a hole for a drain plug. That's of course, after switching to 3.73s.