Broken Transmission Dip Screw

[hdevera]

I attempted to check my transmission fluid level for the first time (<150 hrs on engine).  The bolt which contains the level indicator loosened but does not back out and now does not tighten.  A mechanic told me that I would need to have the bolt drilled out, but in order not to have the fillings get into the transmission, I'd need to remove the transmission casing.  A machinist could then weld a new threaded hole for a new bolt.  My question is [and I think I already know the answer):  Does this seem appropriate or does anyone have another suggestion?  I'm hopping that this is covered by the warranty.  The boat is hull number 1554 and I purchased it in Nov 2000.

[hdevera]

Ron,
You're correct.  I think the threads are stripped.  Do you know of anyway short of removing the transmission, to get the bolt out and be able to tighten it?

[dsavary]

This is a method I have used successfully several times in removing stripped bolts. First you need to use a socket wrench, then you will need to slip a very thin piece of metal under the bolt head edges (straddle the threaded bolt). I went to Home Depot and bought a cheap thin puddy knife and removed the center with a grinding wheel. It looked like a two pronged fork that slipped under each side. Slip this under bolt head applying slight pressure upward on bolt head. Now slowly turn the bolt counter-clockwise. Hopefully you will catch clean threads and the bolt with the dip stick canbe removed.  Hope this works for you as well as it did for me. Mine was used on a snow blower engine dip stick but the principle is the same.
Doug.

[John Gardner]

My two cents' worth.  It sound's extraordinary!  If you think the problem is covered by warranty, I would think the less you do, the better - have a professional, or better yet, a Catalina agent do the work.  
If it isn't covered by warranty, I would think there is a high probability that you already have metal particles in the oil.   Even if you were to get the dipstick out and the inside happened to be clean, I can't think how you might repair it without the risk of dirt ingress other than by following the mechanic's suggestion. (I'm sorry about this pessimistic thread, but that's the way I see it.)