Stripped the filler thread, best fix?

[vasy]

So I pulled out the filler plug to check the fluid level and it came out ok.
I put it back and slightly (barely) tightened it and all the threads came out.
Now I wonder how to fix it so the seal is tight and it does not leak water. I'd prefer to do it without taking the leg apart.
Can I put a helicoil? What about the Locktight thread repair epoxy?

 

[robert graham]

I'd be willing to pay an experienced mechanic to install the correct Helicoil.....if you've never done one there's always a chance of wrong size or screw up....I can't imagine it would cost more than $20 to get it done right....

 

[Bondo]

Ayuh,..... A 3/8"- 16 heli-coil is the cure,....

Donno 'bout tappin' it In-place though,... Bits of metal could fall into the drive,...
Pullin' the top cap would no doubt be the best plan,....

 

[vasy]

Ayuh,..... A 3/8"- 16 heli-coil is the cure,....

Donno 'bout tappin' it In-place though,... Bits of metal could fall into the drive,...
Pullin' the top cap would no doubt be the best plan,....

Pullin' the top cap--- that sounds painful, this would involve removing the lower unit and splitting it?

 

[bruceb58]

What year and model is your omc?

 

[vasy]

What year and model is your omc?

Can't recall off hand. It is the last generation 1995, same model as Volvo-Sx, just has OMC sticker on it.

 

[bruceb58]

I would just look for a used top cover

 

[vasy]

I would just look for a used top cover

Ya..... not in the books
I was hoping someone would have experience with using lock-tight epoxy to fix thread as that would mean to taking apart anything.
I'm trying to find a local boat mechanic here but with the season heating up, might not be till next September - October as we only have two around without driving for hours.
Since this seems to be a 3 step hole, one space for O-ring, one for thread and one slightly smaller one just the hole below, was contemplating sticking the expending ear plug to catch the debris, drill out the hole and tap and put a cut-down heli-coil, vacuum out the metal shavings and remove the ear plug.
At worst I wonder if the plug would fall it, it is so think would gears just shew it up and just not care about little bit of foam inside?

 

[bruceb58]

Very easy to take the top cover off. 4 bolts. Take it off and then do your repair. Their is a very large o-ring that you should replace before putting it back on.

There is a new cover on eBay but it's $350! No used ones on eBay that I could find but might check some online places that sell used Volvo parts.

 

[vasy]

Very easy to take the top cover off. 4 bolts. Take it off and then do your repair. Their is a very large o-ring that you should replace before putting it back on.

Thanks for the info. I took the cover off last night, so helicoil will go in. Best used price I saw for the cover was $150 (ouch)
I already have a used one so might as well repair it.

Two questions: 1) Do you know the part number for that rubber gasket?
2) Do you have the part number for the thin metal spacers that go between the cover and the whatever is under it. They came out, fell on the floor and got bent

 

[bruceb58]

You need to reuse those. They are shims and are varying thicknesses and need to be exact.

gasket look like this?
https://www.amazon.com/GASKET-GLM-Pa.../dp/B004AR1620

Item #16 here:
http://www.volvopentastore.com/Upper...view_id.792035


Shims are item #2 here but they have to be the exact thicknes for what you have in there now
http://www.volvopentastore.com/Uppe...on_id.406663577--store_id.366--view_id.792039

 

[gm280]

Actually if you can't insert a helicoil, you could always go up in size and re-thread the hole for another larger thread size and repair it as well. And it would work forever too. So many ways to skin a cat...

 

[vasy]

You need to reuse those. They are shims and are varying thicknesses and need to be exact.

gasket look like this?
https://www.amazon.com/GASKET-GLM-Pa.../dp/B004AR1620

Item #16 here:
http://www.volvopentastore.com/Upper...view_id.792035


Shims are item #2 here but they have to be the exact thicknes for what you have in there now
http://www.volvopentastore.com/Upper...view_id.792039

Yes, the gasket was bang on..

For the shims I get this: "The Volvo Penta Online Store is only accessible to visitors located in the United States**. Please contact your local dealer for information concerning Genuine Volvo Penta parts "

Can you give me the part number for the shims? (I'm not in the USA)
Thanks

 

[bruceb58]

Here is a screenshot. You will have to measure the ones you have to get the correct sizes.

 

[vasy]

Here is a screenshot. You will have to measure the ones you have to get the correct sizes.

Fantastic! Local dealer has shims in stock and will measure what I need.
Gasket they will order for tomorrow in and install the helicoil.
Hope be ready for Sunday, the sun is out, time to go boating

 

[vasy]

Agrh, not so fast......
So the dealer had 3852371 (0.005) in stock but the 3852369 that I need is Obsolete and they told me that they don't have a replacement or a suggestion.
that shim I need is 0.003.
On ebay I can find 3852370 which is 0.004, I understand that it is a little thinker but will it work? the current one is ripped in half
I can also find a listing for 3852368 which is 0.002.
Suggestions? or does someone have the right part sitting around?

 

[bruceb58]

Instead of using a 0.005 and a 0.003, use 2 of the 0.004. Total thickness needs to be the same.

 

[vasy]

Instead of using a 0.005 and a 0.003, use 2 of the 0.004. Total thickness needs to be the same.

I wish, can't find 2 and 4. But I did call around several local dealers and one had one 3 hidden away on a dusty shelve.
Man, $2 part but I can't imagine the next poor sole that needs one in my area.
Also the top cover is $500 (Canadian) and best used price is $150 usd, about $200 cad.
So tomorrow will stop by a local auto parts store and experiment with the Helicoil.
Boat dealers wanted about $150+tax to install it and would still not provide any guaranty it would be done right. oh well.
If all else fails, will get a used cap.

 

[Bondo]

Total thickness needs to be the same.

Ayuh,.... Bruce's advice is dead-on,.... The total thickness sets the bearin' pre-loads,...

Alittle more, or alittle less could easily spell disaster,...

So tomorrow will stop by a local auto parts store and experiment with the Helicoil.

I don't do these drives, but every drive I've ever worked on uses 3/8"- 16 for drive fills, 'n vents,....
Yer dipstick might complicate things,... Donno,....

I suggest ya buy the drill size stated on the heli-coil package too,....
It's a Must Have, for successful heli-coil implants,...

'n if you can find it,.... Hi-strength Lock-tite for the heli-coil,...
I've been buyin' the lock-tite in a chapstick tube, insteada the liquid in a bottle style,...
It's a waxy paste that stays where ya put it, no run-off,...

 

[bruceb58]

I don't do these drives, but every drive I've ever worked on uses 3/8"- 16 for drive fills, 'n vents,....
Yer dipstick might complicate things,... Donno,....

They are completely different than a standard thread used on other drives.