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 unmitigated 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. Like some particularly lazy checked-out senior short-timer engineer turned the plug project over to their sophomore engineering student intern who took the eeeeeeezyest stuuuuuuuuupidest most idiotic possible way out that they could in between their beer pong parties, then the senior didn't check their "work", and now that it's enshrined in the hallowed halls of the drawing vault, it's near impossible to set right anymore. And THEN, some other mfr saw it, and counted some pennies, and "saw that It Was Good", and now TWO mfrs have that dog dung in their product.

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!

 

Are the ones I posted above for the Dana44 on the Jeeps that would work?

 

​​​​​​​Not sure. Measure your hole, then find size of the plug for sale. Gonna have to make a little more effort on your own I think.

 

I thought someone here would know. You know… fellow 3rd gen enthusiasts helping other 3rd gen enthusiasts. Thanks.

 

Four different 3rd Gen enthusiasts just offered you good advice in this thread. In the time it took you to post in this thread you could have measured the hole, found your replacement, and clicked "submit order". Just go do it. Or choose the harder, but permanent option and go the welded in steel bung option. There, more help given. You are welcome.

 

Could also buy an aluminum diff cover for it. Has all the cool stuff

 

Still no help. I must be the only person replacing the rubber plug on his BW 9-bolt after it was discontinued by GM. Yes, the plug that’s in it now I purchased from a Chevrolet dealer back in the mid ‘90’s right after I bought the car.

I thought someone here would know if the plugs on Amazon would work since they are for the Dana44? on the Jeeps and Mopars etc. They didn’t give out measurements in the description.

Now, I have to measure the plug or take it out and go to a parts/hardware store and match it up. I don’t mind doing that, but if I knew the specs I would give out the information. Why give me a hard time just for the simple question of asking would the Amazon plugs work?

I don’t want the welded steel bung option. I’m trying to keep this car original and the OEM plug I bought back in the mid 90’s lasted for almost 30 years. I just want to replace it since it’s showing a little weathering and I’m restoring with whole axle, new paint and putting in new axle seals.

 

Nope, not the only person trying to replace your discontinued 9 bolt plug. Just the only one too lazy to measure and search Google/Ebay/Amazon/ whatever for that size.

See above. I did it, and in less than the time you have spent complaining about nobody helping you I had it measured, ordered, and arrived at my door. YOU need to make a SMALL amount of effort, just like I did a few years ago.

Think nobody is helpful enough? MEASURE AND FIND IT YOURSELF, then repost here with the results and be the person you complain nobody else will be.

There is an old saying: Give a man a fish and you feed him for a day. Teach a man to fish and you feed him for a lifetime.
People react to that in two different ways. They eagerly learn to fish and feed themselves and others, or they throw a hissy fit at the man trying to teach them fishing and demand society continue to just feed them fish. You choose which person you want to be.

 

as soon as I read this I searched for an aluminum girdle and found one in 30 seconds and had to order it.