Lower Unit Plug Repair--STEP 1

[macojoe]

I had to do this 20 years ago on a 74 Johnson,

After you get that shaft out you will need some long snap ring pliers to get the rest out.
I used needle nose vise grips and ground the tips small this way I could grab the split ring and then use the screw on the handle to closer up the ring so it comes out, same for going back in, put it in and unscrew to let the ring open back into place.

its easy when you get there, just drill and tap new hole, clean all meteal shavings out and reassemble.

Good Luck!

[TheSpecialist]

Won't that require a larger plug??

[Van]

MJ, I'm not going to remove the shaft. I can get to the back side of the hole and put a rag there or someting to catch the drillings. I heard putting heavy grease on the drill bit keeps more filings on the bit.
I might just clean out the case with brakecleen when I'm done to make sure all the pieces are out.

Spec, its not going to be a regular plug like we have now, the 1/4 npt is larger than the hole there now.
If not, I can go to 3/8" npt also, but I should be OK. As I progress we shall see.

I will post as I go.
I wnat to replace the shaft seal before I'm done too.

[Raider Ronnie]

How the heck did you strip the plug anyway???
Your motor isn't that old !!!

[thefishingfreak]

whats the problem? it leaks during pressure test? looks like a decent fix there. maybe you got the wrong washer in there.

take the helicoil out and put a bigger drain plug in there. your gunna need a bigger plug anyways if you start drilling.

[thefishingfreak]

the helicoil is crooked, i read too fast..


the case is soft enough a good tap should cut nicely without the drill.

[Raider Ronnie]

Looks like an excuse to get rid of that loud,gas guzzling, smoky 2 stroke and get an etec or a 4stroke if you ask me !!!

[Van]

Originally Posted by thefishingfreak

whats the problem? it leaks during pressure test? looks like a decent fix there. maybe you got the wrong washer in there.

take the helicoil out and put a bigger drain plug in there. your gunna need a bigger plug anyways if you start drilling.

The shop that put the coil in said there are no plugs that are bigger, even from another manufacturer. The coil was so crooked I could see the impression in the plastic washer all on one side.

The problem is if I go to another bigger machine thread the head will be huge for that diameter and it will stick way out of the LU. So I think the good solution is the tapered pipe thread and a NPT plug. We use these things at work to hold thousnands of psi. It should hold fine for under 20. If all goes well it will be recessed just right and there will be very little flow disturbance in front of the prop.