Quick fix advice for gearcase

[MajBach]

Hi guys. At the beginning of the season, I ate the drainbolt threads on the gearcase on my Honda 90. There was sufficient enough meat left to hold the screw but I knew the next time I took it off, there might be a problem. Sure enough, I failed to mention this to the shop that did some maintenance a few weeks later and the bolt got stripped. THey put in a heli-coil and a Merc bolt. I have not been able to get a good seal since. When I change the oil, there is about a day or so of slow leakage - probably from positive pressure in the housing - but eventually water gets in and I have to change it again. We originally used a Merc o-ring on the screw. Then I tried a Honda one - which required me to drill the I.D. a little bigger. I have also used teflon tape and doubled up on the o-rings. I am still having to change the gearcase oil every other trip. Any advice to get a seal that lasts the season?

 

[TOHATSU GURU]

Re: Quick fix advice for gearcase

A real fix would be to find a larger screw and just go a little more oversize. Drill and tapping it would not be difficult. Whether you use a o-ring, gasket or compression seal would be up to you, but anything should work. Slightly countersinking the housing will not be an issue.

 

[sbbloom69]

Re: Quick fix advice for gearcase

Could there be some leakage around the Heli-Coil threads (where it threads into the case metal) that the orings aren't sealing??<br /><br />Stu

 

[chicken louie]

Re: Quick fix advice for gearcase

there is a product called jl 2000 that is quite remarkable, its a brazing rod just need a propane torch and a wire brush and the original plug. made by new technoligy products.<br />well worth checking out for all kinds of aluminum repairs. you can fix a 1/2 inch hole in a pop can in two minutes.stronger than the aluminum your repairing.