Rear Differential filler plug

I did a search but couldnt find anything.

So I did some work on my jeep yesterday and changed out the front and rear differential oil (which it can be safe to say that it has never been changed in its 37 years of existance as evident by the mud color, burnt smell, and general sludge consistancy of the oil)

My question is this, I replaced the oil and put the differential cover on and was putting the filler plug back in but it wont stop screwing in. The front filler plug could only be screwed back in so far, then it stopped. But the one on the rear diff wont stop, it keeps going.

Is this correct?? Honestly it worrys me a bit, I even pulled it back out and checked the threads on the plug and the hole to see if it was stripped, but its all in good shape.

 

Just put thread sealer on it and be done. I have one like that too and that's what worked for me.

 

They use a tapered plug, basically a pipe plug to seat into the threads in the cover. They are supposed to get tight before they thread in too far. It's common for the plug to get overtightened and stretch out the threaded hole in the cover. I'd recommend a new cover. I think I've gotta couple of spares in the garage for Dana 44's and have the plug. I'd give you one if you pay shipping. PM me if you're interested.

 

Pm sent.

So if I put the thread sealer on it for the time being will it be ok to drive? I have to drive it back home on Monday (about a 50 mile trip) where it will stay for the winter while I put a new wiring harness in it.

 

yes it will be fine . just wrap that sucker with teflon tape and it might weep a touch once hot and running , but it will get you by.the oil is lower than the plug so while it sits in the garage for winter it won't leak.

 

The rear cover on a CJ 44 is fairly thin metal, and I can understand how the hole could get stretched out.

Aside from Nick's generous offer, you could replace the thin rear cover with a factory front Dana 44 cover. That will be made of thick steel, like the front cover.

Not very expensive: http://www.bjsoffroad.com/CartGenie/prod-431.htm - if you join www.ifsja.org you will get a modest discount on purchases from BJ's. This is the one I have on the rear of my CJ-6.

 

Is this cover the same front D44 as one might find on Wagoneer's, Scout II's, etc.?

 

I presume so. I'd have to measure the cover on one of my J-trucks to be sure. I know they both have a thick front cover.

The main advantage is that this is a new cover, from Dana, it comes with new hardware and a gasket, and you can buy it from your desk. A used cover from a front 44 should be significantly cheaper, if you have a source.

 

I ordered a new cover for my CJ6 dana44 rear, and from new the plug would thread right through without much resistance.
I also had to use teflon tape to tighten it to some extend, but I can't run it yet, so don't know if it will leak or not.

Seems like they don't make them like they used to.
If only I knew about the thicker front cover!

Good info on this forum again!

 

Make sure and check the location of the filler hole when swapping used covers front to rear. The front ones on my Ramcharger and W200 Dodge have a higher fill plug than the rear on my DJ-5a. Might cause a leak where one was absent previously.
There are also some shoulder type fill plugs that bottom out on the cover, or use a Spicer rubber plug and skip the threads entirely.

 

Went the teflon tap route on my rear Dana 44. Found like the rest of you my drain plug would keep turning all the way in. No leaks at the plug location so far. Wish I could say the same about leaks on my Dana 20 transfer case.

 

Well I wrapped the plug a couple times with teflon tape, once I get her running with the new manual choke set up and the top back on Ill take her for a spin and check for leaks.

Thanks for all the help guys!

 

when i put my diffs together i had the same problem also about them screwing in all the way. I did not llke it. I found out that a small bung hole plug from a 55 gallon drum is the exact size as a factory plug. The bungs have a flange on the outer edge so they cannot go all the way in. Just use some thread tape on them when you install them. you have to use a large flat screwdriver to instal them. worked great, no leaks looked kinda cool.

 

Well I took her out for a spin today, pulled in teh garage to check for leaks and none were to be found.

However a few other issues popped up that I now need to take care of

 

However a few other issues popped up that I now need to take care of [/QUOTE]

this is normal ,,,don't worry ,you'll get used to that

 

Exactly. While cleaning out my storage shed last month, I threw out a D44 cover from a 98 Dodge W1500. The filler plug hole was situated higher than a Jeep 44 cover.

 

The only ones to truly worry about is a cover from a high pinion front from a Ford. They have the fill plug way up high. Personally I prefer the covers with the fill plug slightly higher than some of the really low ones from the early Jeeps. Reason is if you have to angle the drive pinion up for driveline angles the pinion bearings have a nasty habit of starving for lubrication. With a slightly higher fill plug that allows more oil in the housing to help combat this. If the slightly higher fill plug "causes" leaks then you had a seal on the way out anyway. Shoot, my boss has had a high pinion cover on his low pinion Chev 44 front for 15 plus years. The way I realized it was when I pulled the axle shafts to replace the u-joints and oil started coming out. He didn't realize it either as it was an aftermarket chrome cover he had someone not in-the-know install for him.

 

My concern with the teflon tape method is that over time and hard use the plug can eventually work loose. If it falls out then you may starve for oil. If it works it's way inward, which can happen if the threaded hole is stretched that far, then you are headed for catastrophic failure. It can work as a temporary band aid, but that's all it is, temporary. With the cost of gears, rebuild kits, etc. these days, do you really want to trust all that money to teflon tape? Covers are relatively cheap. I've got a couple more decent used thin covers if anyone wants to replace their bad ones. Just pay shipping. I'd rather that than someone relying on some sealing tape to keep their diff together....

 

this is normal ,,,don't worry ,you'll get used to that[/QUOTE]

Drive..Fix..Drive..Fix..Drive..Fix, welcome to CJ ownership.

 

Would it be easier to go the hardware and get pipe plug or just put a small tack weld on the last thread so it can't go in too far?