Re: stripped threads on lower unit for gear lube plug
Take it to a machine shop and have them put a "helical coil insert" in it. They will overdrill and tap the hole and screw this stainless thread in that will match your "new screw's" thread.......installed with your "new seals". Probably not cost more than $40.
There will obviously be some metallic particles wind up inside, but if you flush it out real good (with regular CC oil) you should be able to flush out most if not all the chips. The chips are alum and since it is much softer than the SS in the lower unit parts, shouldn't be a concern; I wouldn't be concerned if mine.
To flush out, I'd just pump in oil just as you were doing a normal fill, but keep pumping and overfilling until the outlet from the vent hole is clear of any metallic chips.
The gasket won't cover as much thread as before but will probably work just fine.
I'd check the oil periodically for water until I was sure that the gasket was holding. Easy to do, just remove the lower screw [after the engine has been sitting vertical for (say) a week], and if water comes out when you momentarily remove it you need to take evasive action. If oil only, you are good to go.
Beats buying another lower unit. Besides, even if it fails, you can change your lower unit oil on a semi-annual or quarterly basis and run it a very long time. Lower unit oil is designed to stick to the metal parts preventing any water from touching them so frequent changes should do the trick.
The other thing that would help would be to insure that you didn't leave it sit for an extended time without running. Runnning will keep the oil stirred up and in contact with the metal.
There are a lot of lower units out there that have water in them, have had for years, and still work satisfactory. So it's not a life and death thing.
One word of caution however, if you do find water, you need to keep in mind that water freezes and expands in the winter. But a few drops of water aren't going to tear up your lower unit.
HTH
Mark
