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Helicoil upper oil level plug on gearcase

J

jstin

New member
"ARGH!!!!

I just rebuilt

"ARGH!!!!

I just rebuilt the carbs on my 1989 60hp Evinrude, she running better than ever. I went to change the gearcase lube and the top oil level plug stripped some how, when I backed it out the threads from the case came with it. Can this be helicoiled? If not, what are my options?

Thanks,

Jstin"
 
You can try running a tap thro

You can try running a tap through the hole and possibly saving enough threads for it to work. Or go up to the next size in metric and put in a new plug/screw.
 
"Whatever you do, I would pres

"Whatever you do, I would pressure test it before you use the boat. Cheaper to replace the housing that the housing and contents."
 
Is pressure testing something

Is pressure testing something one can do at home? I have an air compressor. Do the shops just remove the drain plug and use an attachment to a compressor? My local marina said it'd be $45.00 and be 2-3 weeks til they could do it.
 
"I made a fitting that would s

"I made a fitting that would screw into the oil drain hole by purchasing a brass threaded air stem at the auto parts store. I re-threaded the end to the same thread pattern as the plug. Wrap it with teflon tape and screw it into the hole. Pump in 15 lbs of air pressure with a hand pump. If the lower unit is still on the motor, check for pressure loss with a gauge. If lower unit is off, stick it in a large bucket or garbage can of water and watch for bubbles."
 
"What Doug Bryant said. Boats

"What Doug Bryant said. Boats U.S. sells a lower unit pump kit that has the metal version of the fitting included. The tester is easy to make. Make sure you "inflate" to no more than about 8 lbs, otherwise you will damage the seals. The only real place you will be checking is your top drain plug. A container of bubble soap that you can steal from the kids works well for this."
 
Many times in the past I have

Many times in the past I have successfully helicoiled the gearcase plugs. Thread is 3/8" 16 tpi. This is one of the few areas where I use loctite on the insert to ensure proper sealing of the gear case.
 
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