Howdy all,

The threads in my oil vent plug hole (upper plug, not the bottom drain plug) are stripped. The plug itself is okay. Can the threads be repaired? Is there an oversize drain plug available?

Advice and ideas are welcome.

Thanks,
Steve

Had this happen to a friend last season with an Alpha drive. He pulled the drive, had it gutted, and took it to a good welder to be welded up and re-tapped. Since his boat sits in the water during the season, we figured this was the best method of repair to ensure it wouldn't leak.

There are thread repair inserts out there made for applications that need to seal air or fluid. You would need to separate the drive (upper from lower) and very carefully ream the hole and tap it for the insert. I usually use "sleeve" grade locktite to seal them in so they don't leak. You would need to thoroughly flush your outdrive after installation to make sure there are no metal chips in it when you are done. Although I've never used one to seal an outdrive, I have used them for hydraulic ports, and oil, air, and water ports on molds as well. All of those are pressure type applications, and I've never had a problem when installed properly. If I get a chance, I'll try to look up the thread size and see if one is made for it. The kits usually run about 60 bucks per thread size, which is dirt cheap compared to a disassembly, weld, repair, and reassembly job.

Forgot to mention that the sleeve-grade loctite is about 25 bucks a tube.

That would be greatly appreciated.

I was hoping for a solution that doesn't require disassembly but I guess Murphy won't allow that.

I've used epoxy (jb weld or devcon) for repairs like this in the past. I just make sure that the aluminum housing is clean. Then I coat the plugs with some oil. Put epoxy on the remaining threads in the housing and screw the plug in. A day later, I pull the plug and makes sure that everything looks ok. You use the epoxy very sparingly to make sure that you don't get a bunch insisde. It's a cheap and easy fix when you're in a bind.

Rene

Thanks, I will give this a try. I'm trying to delay pulling the drive until the end of the season.

Devcon is a good one to use. Just be sure you don't get any inside your drive! Be careful to coat your plug with something as Rene says, or you'll be drilling it out later!

Is Devcon readily available, like from the local auto parts store?

I haven't ever seen it at the auto parts store. Graingers will have it. You should be able to find it on the net as well. It is called Devcon Plastic Steel. It is better than JB Weld, but a little harder to find. Make sure that the aluminum is very clean (acetone and a clean rag) and that the screw and washer are well coated with oil before you put it together and it will work great. The worst that's ever happened when I have done this is that the new threads are easy to strip compared to the old.

Rene

Found the Devcon at a local tool supply house. I bought manufacturer #10610, Aluminum Epoxy Putty. Their web site said it is for filling aluminum and can be drilled and tapped. I hope that's the right stuff 'cause it cost me $46.63 for a 1lb can (their smallest size).