busted thread in gearcase dipstick hole

[Dr Noob]

'02 volvo penta 5.0gl i/o
i managed to completely kill the entire thread in the dipstick hole in the outboard's bearing cover. its the hole where the gearcase oil dipstick screws into. i guess that i used to tighten it too much, and that degraded the thread over the years. i hastily purchased the new cover (3854401, item #15 here: http://www.volvopentastore.com/Uppe...*****.225525168--store_id.366--view_id.331348) along with its accompanying gasket(3852317), thinking that it would be easy to replace. but when i was about to swap it out, i realized that perhaps it is not so easy. so what are my options? i figured that re-threading the hole is out of the question, as i would need a different dipstick, which simply does not exist. so what i would like to know if this can be accomplished by someone without the use of air tools, or should i let the service folks do their deed? if former is the case, do i just simply unscrew the old cover, pry away the old gasket, then plop in the new gasket followed by the new cover? and if so, where can i find out what the nuts should to torqued to? the clymers manual does not reference this particular part directly.

thank you!!!

 

[Don S]

Re: busted thread in gearcase dipstick hole

The clymers manuals are just plain junk. They are used for knee pads, not maintenance manuals.
That cap is not hard to replace, you just need to re shim it per the OEM manual. http://www.4shared.com/file/50982625/e2bdb42c/SX_DP-S_Service_Manual.html

Go to page 123 of the manual, the only special tool you need is a feeler gauge. Be sure to use a new gasket when installing the cap.

 

[Dr Noob]

Re: busted thread in gearcase dipstick hole

wow, the OEM manual. its like i am seeing colors i have never seen before. no more sore knees for me, eh?

but seriously, thank you for such valuable info! looks like i am going to have to buy all 5 versions of that shim just to be sure.

one concern, though. the oem manual makes no reference to the gasket. according to some online images, the gasket should be placed below the shims. yet the manual states that the shims should be placed "... on top of the upper bearing". please clarify this one for me. thank you!!!

 

[Dr Noob]

Re: busted thread in gearcase dipstick hole

The clymers manuals are just plain junk. They are used for knee pads, not maintenance manuals.
That cap is not hard to replace, you just need to re shim it per the OEM manual. http://www.4shared.com/file/50982625/e2bdb42c/SX_DP-S_Service_Manual.html

Go to page 123 of the manual, the only special tool you need is a feeler gauge. Be sure to use a new gasket when installing the cap.

i got the replacement bearing cover and removed the older one. it is at that point i noticed that there were no shims in place. should i still place the shims, or just replace the cover?

also, the rubber gasket looks brand new. should i still replace it as well?

thank you!

 

[Don S]

Re: busted thread in gearcase dipstick hole

Yes, replace the gasket. You have to check the shimming of the new cover.
The new cover may be machined different than your old one.
Without any shims to choose from, a depth micrometer would be the tool to use to get the same information as shims.
IF you have neither, get a VP dealer to measure it for you and get it shimmed right.