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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 weld-
ing repairs to the sterndrive or transom shield.
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 cyl-
inders, trim cylinder attachment, power steering cyl-
inder attachment, power steering cylinder, and the
area around the suspension pins. On or around pre-
cision machined surfaces or precision parts.
Parts which can be welded
1.
The neck of the flywheel housing for the attach-
ment 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.
4.
The exhaust channel in the intermediate housing
except at the steering spindle and around the up-
per 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, how-
ever, it is important to maintain the channel pro-
file. The correct profile is important to prevent re-
stricted water flow to the engine. The exhaust
outlet, trim tab and propeller cone may be weld-
ed. It is important to protect the rubber exhaust
flap during welding.
6.
Pressurize the housing after repair. See chapter
Pressure and vacuum testing.
Repair instructions
Dismantle and clean the damaged part of the stern-
drive. Grind the area to be welded according to in-
dustry 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 weld-
ed, 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. Al-
ways pressure and vacuum test the sterndrive as an
assembly before returning to service. The shaded
portions of the sterndrive and flywheel housing indi-
cate where welding is permitted except where noted
above.
