See full version: Tohatsu/Nissan Lower Unit drain plug gaskets
Where can I mail-order the drainplug gaskets from at a reasonable price? I've tried the local dealer who sold me yamaha gaskets that just don't seem to be the right size, although they insisted all the Japanese outboard motors are the same size.
You can get them at any Tohatsu/Nissan dealer. We have them on the shelf. FWIW, the Yamaha gaskets should be approximately the correct size, as your local dealer said, though the Tohatsu gaskets fit really well.
Re: Tohatsu/Nissan Lower Unit drain plug gaskets
My motor is a 1977 Johnson 55 horse and uses 3/8” drain plugs with 16 TPI. (Threads per Inch) Be sure to find out the correct size and TPI for your motor. [links]
Now take your drain plug and screw it into the heli-coil without the washer gasket on the plug. Count how many coils you have extra on the coil. Remove the plug and cut those coils off with some sharp side cutters. (Don’t cut off the drive tang from the other end). Mine needed 3 coils cut from the heli-coil so it would fit. When you drive the coil into it’s new threads, you want none of the coil to stick out from the hole or your plug washer gasket won’t seal.
To be sure to have all the shavings and chips out, I rinsed the lower unit out with the milky mineral spirits using my lower unit gear oil pump. I put the hose in the top vent hole and pumped the spirits in, allowing it to run out the drain. This flushed out all of the older particles and more of the fresh shavings from the tap job. I then used my air and blew air in form the top until nothing came out the bottom, just to get all the spirits out.
Refill lower unit with fresh oil, put your drain plug in it’s nice new steel threads. more
Auto parts house for a 3/8 16 TPI Heli-coil kit that comes with coils, coil driver tool and the tap. (Expect to spend $20-25) The package will tell you what size drill bit you need for the job, mine was a 25/64th.
Next step was to drill out the drain hole in the lower unit. None of us wants a bunch of metal shavings inside out lower unit with all the gears and bearings. I used a shop vac held next to the hole as I drilled. Recruit someone to help or strap the hose on the unit so you can use both hands on the drill. [links]
Now take your drain plug and screw it into the heli-coil without the washer gasket on the plug. Count how many coils you have extra on the coil. Remove the plug and cut those coils off with some sharp side cutters. (Don’t cut off the drive tang from the other end). Mine needed 3 coils cut from the heli-coil so it would fit. When you drive the coil into it’s new threads, you want none of the coil to stick out from the hole or your plug washer gasket won’t seal.
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