Starter Bolts Broke

[91whitestang]

Re: Starter Bolts Broke

I am a retired Crane Mechanic. I used to work on barges and rigs offshore and when I had to drill out broken bolts (which was quite frequent) I always used a Masonry Bit not a metal bit. It sounds crazy but it works, most of the bolts on the rigs were made of spring metal which is quite hard, which is why I used a masonry bit because they would not dull as quick.

Thanks for the advice, if I can't get it with a metal bit i'll try that before I go to the last resort of pulling the motor. Would have never even thought of using one of those, thanks, Jeff.

 

[Miroash]

Re: Starter Bolts Broke

I am a retired Crane Mechanic. I used to work on barges and rigs offshore and when I had to drill out broken bolts (which was quite frequent) I always used a Masonry Bit not a metal bit. It sounds crazy but it works, most of the bolts on the rigs were made of spring metal which is quite hard, which is why I used a masonry bit because they would not dull as quick.

My Uncle worked on Rigs too, and he always told me to use masonry bits to drill out bolts. I always thought he was joking. Guess not, lol.

 

[91whitestang]

Re: Starter Bolts Broke

So using a masonary bit is a common deal on somethings for marina's then? I figured I could try the reverse metal drill bit first, if that don't work then try to the masonary, and if that don't work, last option would be to pull the motor I guess.

I'm just thinking only being in the motor 2 years and newer bolts, they shouldn't be that hard to get out if I can get a hole in them and use easyout to take them out, especially if the one vibrated loose and then finally broke or possibly both could be loose. Only bad thing is, both are about a 1/4'' into the block so can't get any vise grips or anything on them until I can get something to grab a hold of. Thanks for the help guys, any more infomation or help is greatly appreciated.

 

[91whitestang]

Re: Starter Bolts Broke

hey guys, just wanted to say thanks for the help and advice, i'm going to start working on it tomorrow morning and see if i can't get the reverse drill bit to work first, if that doesn't work i'll then try the masonary bit and if all else fails, guess i'll have to pull the motor. I'll let you guys know how it goes or if I would need some type of input on something, thanks, Jeff.

 

[rodbolt]

Re: Starter Bolts Broke

forget all the above masonary carp your not laying bricks and you have ONE shot at doing this right.
most all the replacement starters and most in the past 10 years are the small casr high torque gear redudion design.
most folks never look and fewer understand why the block is counter bored or why the starter bolts are knurled.
damage the counter bore in the block and you will break starter bolts forever.
fail to use NEW starter bolts any time the old ones are removed and you get to drill the broken ones.
the counter bore in the block holes in conjunction with the knurl on the bolt help lock the bolt to the starter and the block dissallowing any wiggle.
if you have enough clearene you may actually drill it with the engine in place.
the original and replacement OEM bolts ARE NOT hardend. hardend bolts would snap faster as they cannot flex.
odds are the last tech that replaced the starter reused the starter bolts.
not all high torque reduction gear starters had the stud to mount the bracket but you can find it from Volvo.
the hole in the block is there just not all years and all marinizers utilized it.
its highly reccommended to find them.

 

[Bondo]

Re: Starter Bolts Broke

and when I had to drill out broken bolts (which was quite frequent) I always used a Masonry Bit not a metal bit. It sounds crazy but it works, most of the bolts on the rigs were made of spring metal which is quite hard, which is why I used a masonry bit because they would not dull as quick.

Ayuh,.... Bullship,.... A Masonary carbide bit won't even begin to Cut Steel,... Even plain ole Steel....
'ell,... Masonary bits are Dulled,+ Trashed if you run into a piece of Rebar.....

guess i'll have to pull the motor.

Ayuh,... I'm guessing you Will..... Be sure to pull the Drive 1st....

 

[91whitestang]

Re: Starter Bolts Broke

forget all the above masonary carp your not laying bricks and you have ONE shot at doing this right.
most all the replacement starters and most in the past 10 years are the small casr high torque gear redudion design.
most folks never look and fewer understand why the block is counter bored or why the starter bolts are knurled.
damage the counter bore in the block and you will break starter bolts forever.
fail to use NEW starter bolts any time the old ones are removed and you get to drill the broken ones.
the counter bore in the block holes in conjunction with the knurl on the bolt help lock the bolt to the starter and the block dissallowing any wiggle.
if you have enough clearene you may actually drill it with the engine in place.
the original and replacement OEM bolts ARE NOT hardend. hardend bolts would snap faster as they cannot flex.
odds are the last tech that replaced the starter reused the starter bolts.
not all high torque reduction gear starters had the stud to mount the bracket but you can find it from Volvo.
the hole in the block is there just not all years and all marinizers utilized it.
its highly reccommended to find them.

alright i'll cancel that idea on the masonary bits, didn't think it would work probably but anything is worth a try in my position as what I am thinking. I'm going to try the reverse drill bit, should work I hope. the last guy who put a starter on said he had a marina do it, and the bolts are newer ones, can def. tell that, but they are hardend bolts, so probably why they snapped faster. it is a different smaller starter without the bracket so i think i'm going to end up putting a bracket on it this time to help with vibration and weight issue i suppose. i'll be sure to let ya know how it goes either way iboats

 

[forgedin78]

Re: Starter Bolts Broke

Don't want to drift this thread too much, but I'm replacing my starter as well, and the new starter is easily less than half the size and weight of the old one. In fact its about two inches shorter than the old, making the old back bracket useless.

Do I need to fabricate something new to hold the back of the starter? I was originally thinking that since this new one is so small and light in comparison to the old delco-remy starter, that the two front bolts would hold it on.

But now that Ive read this thread I'm worried that just two bolts in it, will lead to me drilling out broken bolts.

Any opinions? Anyone else changed from the HUGE old delco starter that ways about 20 pounds to the new hi torque starter, that would like to say what they did?

 

[Gary H NC]

Re: Starter Bolts Broke

RodBolt is dead on....Best advice yet.
I have a 3.0 waiting for me to pull the engine because the marina used the old bolts to put a new starter on...Both broke off about 1/2 inch inside the block.

Best bet is to go ahead and pull it so you can do it right.Once those holes are messed up you will never keep a starter on it..

 

[craigvalk]

Re: Starter Bolts Broke

My 88 OMC 3.0 suffered this same fate this morning. I have never touched the starter on it, but those bolts both broke last night, and there is NO chance of accessing those holes with a drill. A very tight bilge indeed.
I am pretty handy, but I have no time to pull the motor, I dropped it off at a trusted shop and have no doubt they are going to have to yank it. I am sure that will be a few hours of labor but what are you gonna do.
I can't complain, this is the first problem ever with this IO and motor in years of use. I will be a few bucks poorer is all. I did notice that there was a bracket that tied the starter from the side to the block and that it was broken off. Previous owner for sure.

 

[91whitestang]

Re: Starter Bolts Broke

just wanted to say thank you all for the advice, got a reverse drill bit and they came right out without even having to drill a hole into them. They were newer bolts so probably an advantage to get them out, and made a bracket for the starter to the side of the block this time so that way I hope I won't have to deal with that again. Thanks!

 

[bamadave]

Re: Starter Bolts Broke

Good job! As part of your preventative maintenance program, re torque the bolts every once in while. Might go a long way in keeping the bolts from breaking again.

 

[Gary H NC]

Re: Starter Bolts Broke

Good job! As part of your preventative maintenance program, re torque the bolts every once in while. Might go a long way in keeping the bolts from breaking again.

That was some really good luck!! Congrats and glad the motor did not have to be pulled!

 

[Link2052]

Re: Starter Bolts Broke

I must say very good info here,but I have one bolt frozen ,I've sprayed with Blaster and tapped I don't want to use heat ,very tight aera. I'ts a Merc 4.3, pulled the riser and manifold ,alt, etc got all the stuff out of the way.
I got the bolt to move a slight bit hopefully not twist, I don't want to pull the engine shoulI be patient and spray and tap or just crank on the bolt and hope for the best. The starter moves left to right so I do have some movement.
Please chime in any info will be of great help
I hope I'm not out of line posting on this thread.
Link

 

[Don S]

Re: Starter Bolts Broke

Time to start a new thread with your question.