I'm trying to replace the impeller on this motor and I've run into a sticky problem. Somewhere during the last 40 years, someone used a non-OEM screw in one of the water pump housing attachment points. When I tried to remove it, the head broke off. Since I do a lot of work on older outboards, this isn't unusual for me. The problem is that I can't get the water pump housing off. The head broke off the screw because the body of the screw is frozen to the body of the water pump housing. Since the water pump housing is inset into the gear case housing, I can't generate any relative motion between the housing and the screw. I've set up a fulcrum that allows me to generate a pretty good upward force on the housing near the broken off screw, but so far, no luck. I've tried penetrating oil, salt away, heat, tapping on the housing, all with no luck. If I break the housing, it's $75. I could drill out the screw from the housing, but then i'm faced with the problem of getting the screw stub out. Does anybody have any tricks I haven't already tried?
