lower unit drain plug extraction gone bad

[stingray1492]

OK so i really screwed it up..tried the impact tool, torch and even going sideways with a center punch which did work for the vent plug but not the lower. so in i go with a drill bit and ez-out which of course snaps off so i go in next to the ez-out with a 1/16 bit to try to loosen the stuck extractor snapped that too..short story long and 5 hrs later its out and now as you may guess the case is screwed up bits like to follow path of least resistance i guess lol ss plug vs aluminum housing. Talked to the marina they said there is no fix said I'm lookin at 1200 bucks for new lower unit. I spoke with another "boat guy who said to jb weld the plug and fill gear oil from the vent hole just to make sure i keep filling it until I have recomended amount of oil even if i wait a day for it to seep down and fill again. said it should buy me this season and to start saving for a new lower unit.
Any thoughts on this or know of a permanant repair? Alpha 1 Gen 2 4.3 MPI Thanks

 

[stingray1492]

Re: lower unit drain plug extraction gone bad

looking at lower units online some have one size fits all others have gear ratio info do i need to know this? How would I find out what I have? any help would be greatly appreciated

 

[Big flop]

Re: lower unit drain plug extraction gone bad

Could you repair it with a heli-coil ?
Not sure who but someone has a
gear lube plug with bigger threads.
Maybe Suzuki ?

 

[stingray1492]

Re: lower unit drain plug extraction gone bad

thank you for the suggestion

 

[robert graham]

Re: lower unit drain plug extraction gone bad

It's really just a drain plug, the Helicoil may work, but how about drill and tap oversize and make a plug out of a stainless steel bolt,screw or a small pipe plug?...lots of ways to do it! For $1200 I could get pretty darn creative! Make it work, and flush all metal filings out of lower unit before filling with fresh oil. Good Luck!

 

[stingray1492]

Re: lower unit drain plug extraction gone bad

YAY!!! I MADE IT WORK!!! I got a 1/4 npt brass plug from home depot then drilled and tapped the right size.. fit nice but stuck some which i was told would cause an air bubble and prop cavitation. cant see that little bit making a difference but taking no chances i got a ss plug with a recessed alen wrench hole that sits flush. you can check hardware store or JEGS.com.since there is no washer a couple wraps of teflon tape did the trick. it didnt leak oil out without the tape, but I dont want water to leak in. after drilling and tapping I shot a whole lot of brake cleaner up into the hole and let it drain out with some shavings Then pumped a quart of reg oil(figured thinner and less $ than gearoil) and let it drain out twice.Repeated once more with half a quart of gear oil, drained and then filled it up with gear oil. you will need to chage the fitting on the hand pump so it fits your new threaded hole home depot has a 1/4 male npt fitting with a hose barb on one side,just cut the plastic tube on your hand pump and slip it over the barb. works like a charm! I will say to those who have to do this also be careful drilling and tapping there is somethig inside you will hit with bit and tap im guessing the end of the prop shaft.
Thank you both for help on this and thank you to all on this forum for sharing your knowledge on so many other subjects..I know a lil mushy but cant help doin the happy dance saved 1200 bucks!