stripped lower unit gear lube bolt hole

[JTinMO]

As the title states, winterized the 232 and got it all put away a few weeks ago. When changing the lower unit gear lube (Volvo DPS), I found the bottom screw was not tight when I drained the oil. It wasn't loose, but not tight either. Think the service guy got a little aggressive last winter, but placing blame is not the point of this post. I need opinions on the path to fix this.

The bolt will not tighten up enough to compress the o-ring. The threads are stripped out enough to not let the bolt grab. Simple as that. For now I filled up the gear lube and snugged it up, but it's leaking oil very so ever slightly while it sits. It needs fixed before it goes back in the water.

Has anyone had this issue? What's the recommended resolution here?

Google shows me that it looks like worst case is that I need to swap out the bearing carrier for a fix. Didn't know if tapping for larger threads is an option or not. Surely someone here has experienced this?

[Lockey14s]

This sounds like a perfect job for a helicoil. as long as there is enough meat around it, you can drill and tap a larger hole and then insert the coil. the only thing is the sealing surface for the O ring. if the helicoil eliminates this surface then it will leak. id suggest taking the outdrive off for the winter and take it to a local machine shop. carrier bearings are expensive and hopefully you can avoid having to buy one to fix this issue

[AsLan7]

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Did you try jamming toothpicks into the threads while screwing the plug in?

I guess jb weld could be used in a pinch but I think I’d have a professional rebuild and retap that plug hole to make her good as new again. That’s not a source you want leaking —either fluid out or water in.

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[JTinMO]

coming back to this on the warm side of winter......

I took the 232 to the shop to get this situation resolved, and the resolution was way simpler than I thought it was going to be. Apparently the drain hole bolt on my model was a "short" model that was only used for about 2 years, and it only had about ½" of threads that ever engaged in the housing. They are known to strip out. So not exactly a unique problem. The housing hole is tapped with threads much farther (the whole way inside). The resolution is they tapped the threads to clean out the buggered bits, then simply installed an $11 longer (normal) bolt that is used on later model drives, and seals up nice and tight. No need for helicoil, larger diameter bolt, etc. Only had to add ½ quart of gear lube and she's good to go.

Got the impeller changed at the same time so I don't have to worry about that.

The 232 is ready for water now, if we can ever get a boating season this year!

[Big Block Power]

Well that's a great thing. Congrats on the way fix and coming back to this thread.

[akorcovelos]

Love the easy fixes!

[AsLan7]

Thanks for the follow up JT. Great to hear.

[JTinMO]

Well that's a great thing. Congrats on the way fix and coming back to this thread.

I figured I would post the resolution for the next guy that has this issue. I hate finding posts with issues, and no resolutions ever posted to close out the story.

[AsLan7]

Well that's a great thing. Congrats on the way fix and coming back to this thread.

I figured I would post the resolution for the next guy that has this issue. I hate finding posts with issues, and no resolutions ever posted to close out the story.

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+1 my friend.
Thank you again.

[Dank]

coming back to this on the warm side of winter......

I took the 232 to the shop to get this situation resolved, and the resolution was way simpler than I thought it was going to be. Apparently the drain hole bolt on my model was a "short" model that was only used for about 2 years, and it only had about ½" of threads that ever engaged in the housing. They are known to strip out. So not exactly a unique problem. The housing hole is tapped with threads much farther (the whole way inside). The resolution is they tapped the threads to clean out the buggered bits, then simply installed an $11 longer (normal) bolt that is used on later model drives, and seals up nice and tight. No need for helicoil, larger diameter bolt, etc. Only had to add ½ quart of gear lube and she's good to go.

Got the impeller changed at the same time so I don't have to worry about that.

The 232 is ready for water now, if we can ever get a boating season this year!

Trying to revive an older thread. JT...any chance you can find out the new part number they installed? I'm currently dealing with the same problem, and my dealer doesn't know of any "longer" drain plugs.

[AsLan7]

coming back to this on the warm side of winter......

I took the 232 to the shop to get this situation resolved, and the resolution was way simpler than I thought it was going to be. Apparently the drain hole bolt on my model was a "short" model that was only used for about 2 years, and it only had about ½" of threads that ever engaged in the housing. They are known to strip out. So not exactly a unique problem. The housing hole is tapped with threads much farther (the whole way inside). The resolution is they tapped the threads to clean out the buggered bits, then simply installed an $11 longer (normal) bolt that is used on later model drives, and seals up nice and tight. No need for helicoil, larger diameter bolt, etc. Only had to add ½ quart of gear lube and she's good to go.

Got the impeller changed at the same time so I don't have to worry about that.

The 232 is ready for water now, if we can ever get a boating season this year!

Trying to revive an older thread. JT...any chance you can find out the new part number they installed? I'm currently dealing with the same problem, and my dealer doesn't know of any "longer" drain plugs.

.
Hey Dank... Hopefully JT can help you. Any pics of your Cobalt?

...and welcome aboard mate!

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[JTinMO]

coming back to this on the warm side of winter......

I took the 232 to the shop to get this situation resolved, and the resolution was way simpler than I thought it was going to be. Apparently the drain hole bolt on my model was a "short" model that was only used for about 2 years, and it only had about ½" of threads that ever engaged in the housing. They are known to strip out. So not exactly a unique problem. The housing hole is tapped with threads much farther (the whole way inside). The resolution is they tapped the threads to clean out the buggered bits, then simply installed an $11 longer (normal) bolt that is used on later model drives, and seals up nice and tight. No need for helicoil, larger diameter bolt, etc. Only had to add ½ quart of gear lube and she's good to go.

Got the impeller changed at the same time so I don't have to worry about that.

The 232 is ready for water now, if we can ever get a boating season this year!

Trying to revive an older thread. JT...any chance you can find out the new part number they installed? I'm currently dealing with the same problem, and my dealer doesn't know of any "longer" drain plugs.

Sorry, just saw this. The longer bolt is Volvo part number 3851329. I have no clue what the short bolt originally was, but you don't want that anyway.