Help! i broke a screw on the top of cylinder

[henning_dt85]

When I was going to pull off the cylinder-head on my 739,5 johnson to change the gasket i broke a screw, and it broke right down at the surface.<br />The head is mounted with 8 screws, and the one who broke is sitting in the middle ( three up, three down and two in the middle)<br /><br />Is this any problem??<br /><br />Can I replace the rest of the screws with metric screws? ( I will ofcourse not screw it right inn!)

 

[G DANE]

Re: Help! i broke a screw on the top of cylinder

Hi Henning - greatings here from your neighbour in Denmark.<br /><br />Before you start drilling and cutting new threads - take my advise.<br /><br />Do you know anyone who has a TIG welder or is there a little shop nearby that does. Welding a new bolt to the place and cooling down almost always makes it possible to turn the broken piece right out. The heat will expand the bolt into the corrosion and cooling will make it loose. If it doesnt happen at first attempt, make a second. A couple of Carlsbergs usually does it !! I wouldnt replace inches with metric - it belongs there. If you have scrap motors- save every bolt - i do.

 

[Droll]

Re: Help! i broke a screw on the top of cylinder

If not Dane´s advice helps , locate a small hardware store and purchase this (In Norwegian ):<br />1 grispikk passende størelse ( NEW EZ-outs )<br />1 Gjenge tapp (bunntap ) ( taps )<br />8 nye Bolter (tommer) ( 8 bolts (inch) <br />Drill out the old bolt use the NEW EZ-outs (grispikk) to remove the remains , clean all hole with the taps (gjengetapp) ,insert NEW inch bolts ....<br /><br />Sorry about my English didn't remember the names of those tools thanks ted655 <br /><br /> <br />Gjengetapp ( taps )from Clasohlson<br />

 

[ted655]

Re: Help! i broke a screw on the top of cylinder

You might find a "left hand" drill kit. use a reverseable drill and as you drill, you unscrew the broken screw. I'm pretty sure Sears sells the whole kit<br /><br />I see pictures of EZ-outs and taps<br />USA reply

 

[rodbolt]

Re: Help! i broke a screw on the top of cylinder

hello<br /> Gdane gave you very good advice. I drill and tap when I have acsess. if not a friend of mine owns a welding shop and has a special rod desined to remove broken studs. we have removed hundreds of trim tab screws from jonnyrude lowers without removing anything. so if you cant drill it, and make sure of your skill with a drill before atemmpting this. try welding a nut to the broken part. DO NOT and I will shout again. DO NOT try an esy out. when you drive the esay out in it expands the bolt even further into the threads thus making it even tighter. then you will have a bolt that is impossible to remove as well as a piece of hardend tool stell broken off in the middle. wish I had a 5 spot for every one the DIY has brought me with broken easy outs or a hole that was started with a wal-mart chinese drill bit that I then had to figgure out a cure. then they whine when I bill them 45 to 100 dollars to remove the parts they broke .<br /> any way good luck and keep posting

 

[Droll]

Re: Help! i broke a screw on the top of cylinder

How about this one ?<br />

<br />Drill a hole ,knock this rod in ( tight fit), slide on nut ,remove bolt .<br />Have used this with luck many times , does NOT expand the bolt .<br />Don´t know the exact name ,but it is a replacement for the old EZ-out .<br />Shuld be availeble in an good hardware store .<br /><br />If I have learned anything about old outboards , when removing old bolts , you will need some basic tools , 3 or 4 quality taps , sharp drill bits ,and time ,do not rush .<br />Punch a mark in the senter of the bolt , start with a small drill bit , work your way up to the correct size ,find the correct tap size and ....<br /><br />Better this way rodbolt

 

[ledgefinder]

Re: Help! i broke a screw on the top of cylinder

If it broke at the outer surface of the head (the usual place), remove the other seven bolts, and remove the head. You should then have plenty of bolt to grab onto with vicegrips. <br /><br />First, heat what's left of the bolt with a propane torch. Then use your vicegrips. The bolt should move a little. Be patient, using cyles of heat, penetrating oil, cooling, and working the bolt back and forth a bit at a time. I've never had this fail.<br /><br />Once you're done, surface the head (figure 8 motion on 200 sandpaper on a sheet of glass) and the cylinder (LIGHTLY just cleaning it with a file). Clean up & put on your new gasket. The 9.5s are great motors!

 

[henning_dt85]

Re: Help! i broke a screw on the top of cylinder

what do you mean by "grispikk" ( NEW EZ-outs <br />Can I use the (skrueutrekkersett 249,-) from Biltema?? <br />Where can I by the "grispikk" or "EZ" ?? ( Biltema, Thorsov Clas Ohlson)

 

[Droll]

Re: Help! i broke a screw on the top of cylinder

This is the old EZ-out art.nr 19-2248 at biltema .<br />Follow Rodbolts advice , DO NOT use it .<br />The other one art.nr 19-236 ??? maybe , IF the bolt is loose .<br />The best way is to drill out the old bolt , clean out the remains with an tap .<br />To find the parts you need ,look for an oldfasion hardware shop , not Biltema ,Torshov ... they will only have metric taps , it is harder to find inch tools/bolts here in Norway ,but if you want to work on those old outboards you have to find them .<br /><br />If you can´t find it drop me a mail , I can droll@online.no

 

[R.Johnson]

Re: Help! i broke a screw on the top of cylinder

Here is one method I have used when having to use a drill. If you have access to a lathe, turn up a drill bushing that is a slip fit in the cylinder head bolt hole. Bolt the head back in place and push in the bushing over the broken stud. This will keep the drill on center. Make the bushing at least a 1/4 in. longer than the thickness of the head. Make the hole in the bushing the same size as your starter drill, 1/8 to 3/16

 

[wilde1j]

Re: Help! i broke a screw on the top of cylinder

Another suggestion for after you remove the broken remains. When re-assembling, use non-hardening Permatex on the bolt threads so this doesn't happen again.

 

[moganman]

Re: Help! i broke a screw on the top of cylinder

Been there done that. Use an ez out but use the square tipped ones ONLY! Take a punch and punch a hole right in the middle. Use the appropriate size drill bit and drill about a quater inch. Then tap the ez out in with a hammer. Then heat up the bolt a little. Then use a wrench and slowly turn the bolt out. One more thing, soak in liquid wrench overnight first. I have pic of a stud with an ez out in it if you want email me. SQUARE TIPS!!!!

 

[jim dozier]

Re: Help! i broke a screw on the top of cylinder

I must respectfully disagree with Moganhunter and refer you back to Rodbolts first answer above which I can confirm from unfortuneate personal experience. Having used many an EZ-out in automotive repairs, I once attempted to use an EZ-out on a frozen outboard thermostat housing bolt. The death grip that aluminum oxide in the marine environment has on a bolt shaft is a wonder to behold and usually exceeds the torque threshold of an EZ-out which breaks off rather inconveniently flush with the broken bolt. It then requires a carbide tipped tile cutter (a useful thing to have) in a carefully handled Dremel tool to remove. DON'T use the EZ-out. Try the TIG welder method first and if that isn't possible drill it out with a high quality bit and a center punch and put in a Helicoil Kit.

 

[WoodsJ]

Re: Help! i broke a screw on the top of cylinder

Henning,<br />I tend to agree will all who have said, "STAY AWAY FROM EZ-OUTS". I have just finished having two bolts removed by a machine shop, $140 lesson. While removing the thermostat covers on a 120 evinrude 2 bolts broke off. I then attempted to drill and remove them, only to break off an EZ-OUT in each hole, had I brought the heads to the shop from the start the price would have been 1/8 the final cost. I would go with the drill and tap method you will get it done for minimal expense. Worse case scenario if you take too much metal a helicoil can be installed easily.