1992 30 hp evenrude striped fill plug

[sandspike]

hi, i was changing the lower unit oil and striped the threads out of the fill plug. now what? what can i do

 

[iwombat]

Re: 1992 30 hp evenrude striped fill plug

How badly are they stripped?

Threads kinda there, but not gripping.

or

All the threads came out with the plug.

 

[jtexas]

Re: 1992 30 hp evenrude striped fill plug

part no. 0307551
around $3
check ishopmarine.com

 

[sandspike]

Re: 1992 30 hp evenrude striped fill plug

i can get the plug to screw in but it wont get tight. and most of the threads did come out.but like i said it will screw in just not tight , thanks

 

[iwombat]

Re: 1992 30 hp evenrude striped fill plug

Read jtexas post, then re-read your original post.

Did the threads strip off the plug, or did they strip out of the hole the plug goes into?

 

[iwombat]

Re: 1992 30 hp evenrude striped fill plug

If the plug is damaged, then just get a new one like he said.

If the hole is damaged you have a few options.

Given that you've still got some threads left you might try either loctite or permatex thread repair. You can get that at just about any auto parts store. I'd give that a go-round before anything else.

Other options are heli-coil, or welding and retapping. I wouldn't do either of those w/o removing the internals from your lower unit. Both those options will send metal chips inside the housing.

 

[sandspike]

Re: 1992 30 hp evenrude striped fill plug

sorry, the threads came out of the hole. not off the plug.i will try the permatex thread repair or the locktight. if i use one of those will i be able to get it back out? thanks for all the help.bill

 

[Scaaty]

Re: 1992 30 hp evenrude striped fill plug

In regards to a couple post replies here, come on guys, do you really think the aluminum threads would strip the thread off a steel bolt?

 

[iwombat]

Re: 1992 30 hp evenrude striped fill plug

No, I didn't but I just wanted absolute clarity.

 

[iwombat]

Re: 1992 30 hp evenrude striped fill plug

And, yes you'll be able to get it back out. Part of the kit is release agent you put on the plug so the repair epoxy won't stick to it. I've had moderate temporary success with the stuff in the past. I wouldn't call it a "real" fix by any means, but it just may be enough to get you by.

 

[jtexas]

Re: 1992 30 hp evenrude striped fill plug

In regards to a couple post replies here, come on guys, do you really think the aluminum threads would strip the thread off a steel bolt?

ok, so I'm an idiot, what's your point? 8) jus' kiddin don't answer that. Actually I just figured they wouldn't make the plug out of harder material than the hole...

 

[iwombat]

Re: 1992 30 hp evenrude striped fill plug

Really, I'm glad you caught it. I just naturally assumed the hole was stripped and not the plug. But, if you read the post that's not what it says. It's pretty easy to give totally bad advice based on such assumptions.

Turns out the assumption was right in this case, but still.

 

[R.Johnson]

Re: 1992 30 hp evenrude striped fill plug

Welding will destroy the counterbored seat for the gasket seal. I would drill, and tap one size over, and have a new screw made. That would be the cheap, and easy fix compared to damaging the gearcase further. I would not look for much success with epoxy on that oil contaminated aluminum.

 

[Scaaty]

Re: 1992 30 hp evenrude striped fill plug

Been a Machinist all my life, but sometimes I can't figure why people give advice that is a "well, try this"., or whatever, without know the properties of all things metal. R. Johnson has one fix. What i would do is simply take some JB "WaterWeld" putty, fill the hole up and sand smooth (need a nice, oil free application). What threads are left will see it there for life. Somewhere in the same area (just above/below/side-tap the metal for a clear ring so you don't go into a bearing support-need to see the case myself to be sure) do a 1/4 drilled hole, drill stuck in grease to hold the chips. Now do a 1/4-3/8ths countersink and spot the case for the new o-ring or washer. re-drill (grease on everything again to hold chips), with a "F" drill, and re-tap 5/16th. Round head 5/16ths screw, oring, little blue Loctite....done.

 

[Scaaty]

Re: 1992 30 hp evenrude striped fill plug

Been a Machinist all my life, but sometimes I can't figure why people give advice that is a "well, try this"., or whatever, without know the properties of all things metal. R. Johnson has one fix. What i would do is simply take some JB "WaterWeld" putty, fill the hole up and sand smooth (need a nice, oil free application). What threads are left will see it there for life. Somewhere in the same area (just above/below/side-tap the metal for a clear ring so you don't go into a bearing support-need to see the case myself to be sure) do a 1/4 drilled hole, drill stuck in grease to hold the chips. Now do a 1/4-3/8ths countersink and spot the case for the new o-ring or washer. re-drill (grease on everything again to hold chips), with a "F" drill, and re-tap 5/16th. Round head 5/16ths screw, oring, little blue Loctite....done.

Thought about this, and looked at a couple Johnson lowers I have laying around. Not a lot of meat there, I'd probably go with an "I" drill, and 5/16th -24 tap. Fine thread instead of coarse. And forget the Loctite..really not needed, and with you pushing oil up through it, wouldn't stick anyway. Better to also with the Taper tap to go in only so far, check for fit, go a little father, etc, until it begins to snug up just before the o-ring or flat gasket would touch.
Thats one thing I DO like about the old Force lowers, fill and vent up top, simple small pipe plug on the lower nose.

 

[bben76]

Re: 1992 30 hp evenrude striped fill plug

Here's my solution (untested!)...

I striped my drain plug hole b/c i was changing lower unit oil after every hour of use during the summer b/c the seals were bad and letting water in. wasn't paying attention one time and cross-threaded the lower plug, crap!

looking in the hole i noticed that there was space beyond the threads that could be taped, and wasn't being used by the drain plug b/c they're the plug is so short.

i tapped the aluminum beyond the current threads (made sure I wasn't hitting anything integral) and found a longer bolt to fit in the drain hole. turns out the only bolt that would work has a hex head, so it actually makes it easier to pull in and out.

i'm still replacing my seals so i haven't had a chance to pressure check the lower unit with this solution, but it snugs up nice. here's some pix...

 

[Scaaty]

Re: 1992 30 hp evenrude striped fill plug

That will work just dandy. Looks like a Stainless Socket head too. Might toss some aerated water at the prop, but that will just actually give ya a better holeshot. At speed means zip.......looks good!