Since the 9-bolt oil fill rubber plug is no longer available, what to use to plug the hole on the cover?

 

I ran into this years ago. Measured the hole and searched Ebay. Found one same size, a Chrysler part I think. Someone suggested welding in a pipe plug bung instead. Not a bad idea, but the rubber plug was easy, cheap, and lasted 30+ years so I figure this replacement should last until I'm dead.

 

Yup, the plug in a Dana rear, such as the 44 in various Jeeps, is the same.

Of course, Jeeps leeeeeeek their fluid just as bad as the 9-bolt does. It's a stuuuuuupid "design"; IMO just pure unadulterated unvarnished unalloyed LAZINESS on somebody's part. I can't think of ANY other application in which an educated and sensible engineer would use such a weeeeeeek "system" to retain a critical fluid. It's just bald-faced IGNORANT.

In Jeeps, I usually tap the hole to pipe (½" I think, I could be wrong) and use a brass plug. Unfortunately the hole is already slightly too large for that, so you have to be careful not to tap it very far, otherwise a plug will just screw all the way right through it without ever tightening up. The threads don't need to be very deep. Then of course some sealer can finish up the job.

 

These would work?

 

After having the 9 bolt style rear since the late 80s I have only "lost one" my neighbor suggested welding a small plate with a bung and a metal plug because he could not believe they would put such a plug in any vehicle so yes mine was modified back in 1992, 1999 and now that I have another in my newly acquired 1988 Trans Am once I get it on the road.

 

Sorry, the OEM inspection cover with that rubber plug design belongs in the trash!

How could anyone intelligent enough to implement a Design with Four Spider Gears (instead of the typical Two) allow for such an Inspection Cover Design?!?!

An Aftermarket Inspection Cover is a Must!