Welding Welding on certain parts of the sterndrive and the transom shield is allowed. Extreme caution must be used to prevent damage to the precision machined surfaces or precision parts used in the sterndrive (i.e. near bearing locations). Always use Volvo Penta welding electrode 839643-4 when making any welding repairs to the sterndrive or transom shield.
4.
The exhaust channel in the intermediate housing except at the steering spindle and around the upper and lower bearing positions of the vertical shaft.
5.
The lower unit housing on the cavitation plate and the exhaust channel except around the bearing positions. The lower fin provided no more that 2/ 3 of it is missing measured vertically. The water intake channel at the front of the housing, however, it is important to maintain the channel profile. The correct profile is important to prevent restricted water flow to the engine. The exhaust outlet, trim tab and propeller cone may be welded. It is important to protect the rubber exhaust flap during welding.
6.
Pressurize the housing after repair. See chapter Pressure and vacuum testing.
Parts that cannot be welded WARNING! The following parts are safety related and are not allowed to be welded. The steering fork, steering helmet, clamp ring, tiller arm, suspension yoke and exhaust elbows, trim cylinders, trim cylinder attachment, power steering cylinder attachment, power steering cylinder, and the area around the suspension pins. On or around precision machined surfaces or precision parts.
Repair instructions Parts which can be welded 1.
The neck of the flywheel housing for the attachment of the rubber bellows. Grind the neck smooth after welding to get an even surface.
2.
The transom shield except on and around the suspension ears, steering journals, around the suspension pins and the attachment of the trim cylinders.
3.
The shift mechanism cover.
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Dismantle and clean the damaged part of the sterndrive. Grind the area to be welded according to industry standard for welding aluminum. The welding should not be done at less than 20 ºC (68 ºF). If a part has been broken off and hasn’t been lost, it should be used. Even if the surfaces are to be welded, there should be a V groove approximately 45º on both sides of the joint. Make the repair using Argon welding and Volvo Penta electrode 839643-4. Always pressure and vacuum test the sterndrive as an assembly before returning to service. The shaded portions of the sterndrive and flywheel housing indicate where welding is permitted except where noted above.
