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During a routine sail drive seal replacement on a Fountaine Pajot Helia 44 in Charleston, South Carolina, the crew discovered a loose, deformed nut on the vertical shaft that had been grinding against the horizontal shaft.6:42 A professional mechanic recommended replacing the entire sail drive at a cost of $12,000 plus $5,000 to $6,000 in labor, citing a lack of experience with internal shaft repairs and liability concerns.16:55 Instead, the crew opted for a DIY repair by filing the damaged threads on the vertical shaft to accept a new $22 Volvo Penta nut.14:24 They used generic sockets from AutoZone to press in new lip seals and O-rings, following the workshop manual's dry-installation procedure.2:59 The repair successfully restored the shaft's functionality, avoiding the need for a full unit replacement or expensive specialized Volvo tools.16:01 The experience highlights the cost-saving potential of DIY maintenance over professional quotes that prioritize full-unit replacement.

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