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Just checked my outdrive oil dipstick. As I removed the dipstick I noticed metal within the threading of the dipstick. I pulled a big piece of threading right out of the outdrive. Now it is bare inside. It is as if the threading inside the outdrive just pulled right out. Not stripped really but the dipstick pulled the threading out of the outdrive!

Any suggestions? Obviously the dipstick will not screw tight at all now and will not be putting the boat into the water until I get this fixed. Have the dealer re-thread the drive or what? Please help thx.

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-2006 H180 VP3.0 SS 21p

I hate to say it, but you will most likely have to pull the outdrive in order to fix the threads. You do not want any shavings to get in it. Most likely a helicoil might fix it, if you can get the right thread. Try to get stainless if you can.

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1992 Baja 38 Special Twin 502 Mags

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thanks good information. I read on another forum this was somewhat common. That there's a "shim" that can be used to rethread the outdrive. I think that is similar (or the same) as your mention of the helicoil which I'll look into. I'll probably call the dealer (stealer) on Monday to get their assessment.

It appears the threading I pulled out plus a couple of threads left in the bottom appear to match up in depth. i.e. I don't think any of the shavings dropped into the outdrive but obviously not sure. The magnetic dip stick isn't pulling anything out and the drive oil isn't milky and looks clean like new. Any other advice....has this happened to any of you guys?

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-2006 H180 VP3.0 SS 21p

Yep... Been there and done that with my '07 h200... my drive didn't have to be removed... I ended up taking the top cover off (i think it was 4 bolts), covering it with a garbage bag, and took it to the dealer... He put a helicoil in for $20 and it has been fine ever since (probably stronger than the original aluminum)

When you take the top cover off there will be several metal "shim rings"... don't lose these, as they were measured for a good fit... I think the book even says that when the cover comes off you need to remeasure, but I did not, and mine is sealed tight... just make sure and put the bolts back in with "even tightness" (i.e. don't tighten 1 completely first... do them each in a pattern a little at a time)

Also, don't panic if there is a little water the next time you change your gear oil... mine was marginally stripped and I still went out on the lake.. it came out slightly milky the first time after I fixed it, but after that its been pure gear oil.. I even pressure tested it with an air pump and vacuum tested it to make sure there was no leak.. if it is stripped, water can and will seep in...

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2007 FW Horizon 200 5.0GXi/SX-A

Thanks Skid. After further research on another forum I figured out that I could take the top plate off. Over torque seems to be fairly common. So, like you, I covered the top of the drive with some plastic and taped it as a temporary top cover. I don't remember seeing any shims. Just a black gasket? I dunno maybe I wasn't paying attention.

The dealer didn't want to fool with me on the helicoil basically wasn't helpful so I took it to a body shop today. Luckily, they had a helicoil that fit. Think it was 1/2" - 16 pitch but for anyone reading this have the shop double check before drilling. The shop also put some red (perm) locktite on the helicoil to be sure it doesn't come out and then screwed it in. The helicoil sits just under flush from the top so that the gasket from the dip stick fits just inside the hole. I'll probably put a little silicon just outside the gasket as the hole is just slightly bigger (from the drill press) than the factory hole and want to be sure it is water tight. Overall, i feel pretty good about it. It was $25 fix. The top cover is $300 to replace and the dip stick is...get this...$100 to replace. My only concern is the helicoil sits about 1/4 - 1/2" inside the top cover so I hope it will fit flush when I get everything back together. If not, will dremel it flush. Do you recall if yours was flush or not from the inside of the cap?

Hope this thread helps others out. I'll report back if I have troubles or milky drive oil. My plan is to take it out to the lake this weekend and change the oil AFTER I get it out once.

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-2006 H180 VP3.0 SS 21p

the top needs to be flush.... on the bottom of the top cover plate, i would assume it doesn't matter if it is flush... it just faces down into a giant cavity anyhow... i would not dremel it... just leave it... Make sure and get some brand new o-rings for your dip stick.. the helicoil has a sharp point at both ends of the coil (or at least mine does)... so its good to have some extras (although I have not yet torn an o-ring apart)...

Your shims are likely stuck to the top cover, or to the inside of the drive.. they are perfectly round and smaller than the perimeter of the gasket you just mentioned...

Glad you got it fixed for cheap.. I didn't want a new cover for $300 either

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2007 FW Horizon 200 5.0GXi/SX-A

Found out the hard way the bottom needs to be flush too. Now that the red loctite is dry I'm forced to dreml is out. The top cap sits flush on the bearing so the helicoil has to be flush on both sides. Yea, i found the shims. There's 2 on mine.

anyway, kind of a pain but hopefully this helps it less painful for others. My best advice is to buy a measured torque wrench when tightening anything on a volvo penta outdrive

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-2006 H180 VP3.0 SS 21p

I've heard of others stripping out that plug. I'm not sure if they used a softer grade of aluminum, or maybe the threads were not tapped right in the first place. My old Cobra has a similar design, fortunately I have not had trouble with the bolts stripping out on it. That dipstick only needs to tight enough to seal, no more (like inch pounds of torque not foot lbs).

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88 Four Winns 200 Horizon
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2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

Here's a few pics:

had to snip under the cap so it can sit flush

https://docs.google.com/open?id=0B0xGLD864qKqVF9OY0xBOHUwb3M

here's how it looks from top. (helicoil)

https://docs.google.com/open?id=0B0xGLD864qKqUXlxdjBtbi1DN1k

debating on if I should install this rubber (neoprene) washer on top of the cap. there's already a washer on the dipstick but I want to be sure no water gets in.

https://docs.google.com/open?id=0B0xGLD864qKqQXNRbTV5Q3dyNms

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-2006 H180 VP3.0 SS 21p

Im pretty sure that mine had only a helicoil installed no loctite no silicone sealant etc it was probably flush on both sides cause the boat mechanics had likely done it before the dipstick oring compresses when you tighten it it should be enough to prevent leaks you could always pressure test it with an air pump hooked to the vent plug but if you have a small leak it wont destroy your drive some oils say they can allow 10% water contamination

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2007 FW Horizon 200 5.0GXi/SX-A