My buddy's 2004.5 blew out the rear freeze plug in the block on Saturday. Se this thread: https://www.dieseltruckresource.com/...d.php?t=137584
We got the parts described in that thread to put the flange on the back of the head and do away with the freeze plug, but turns out there is a metal line running around the back of the head and it's in the way of getting that flange placed in the right spot.
Has anyone else tried this, and succeeded?
I'd like to know how others have solved this problem, even if you didn't use the flange.
I did see something about a plate that goes across the back of the head, that would probably fit between the head and the line, and I even saw a ppicture of it, but have not been able to find a part number for it, and the Cummins dealer had not heard of it. They even said they hadn't heard of Dodges popping the rear freeze plug out.

We'll figure this out, but I'd like to hear about any other creative solutions others have thought of.

Thanks,
Chris

 

Have you already checked this thread out???
https://www.dieseltruckresource.com/...ght=blackbeast
PM pourindiesel I think he knows the part number..or if you are a TDR member it looks like there is a link to the part number. I am not a member of TDR so I don't know what the link shows????

sorry that's about all the help I got
from the looks of the pic you could make a plate yourself in about 10 min's

 

We ended up making a plate as described by Jeff K. Thanks Jeff! Of course it didn't come out quite right because we didn't know much about the contour at the bottom, so we ended up custom fitting it with the fire wrench. A couple of washers in the plug itself for support, and tightening the plate pushed it right in. I don't know what it looks like back there, but it sure ain't leaking.
Thanks to everyone who offered advice on this problem. It was helpful.

Thanks,
Chris

 

Maybe someone would like to do a full write up on this for the tech section? Hmmmmm?

 

Wasn't there a recall or campaign about 04.5's with blown freeze plugs? I seem to remember checking if mine fell within the VIN range. I also seem to remember that the fix was a new short block? I can't remember where the info is on it but if you go here:

Recall and customer satisfaction notification

and put your VIN in it will tell you if there is anything outstanding.

 

Just that stupid reverse alarm recall. Not gonna get that one done.

Chris

 

Yes, there was a range of 3rd gens that would be checked for freeze plug leakage.
If I recall correctly, the dealer had to keep the truck overnight so that the engine was cold at the start of the test. The test procedure required a cold start and then WOT to upper RPM limit for a number of minutes until the engine temp had risen to a certain point. If the engine endured this with out any freeze plug leaks everything was considered good to go. If there was leakage then the engine was either repaired or replaced(I can't remember which). I seem to want to lean toward replacement, but my gray hair is getting in the way of my long term memory

 

Wow!! what a stupid test.... take an ice cold diesel and give it a few WOT runs and see if it blows!!