Allan key bolt 1998 75 Force

[TwoFish]

I may need to take the powerhead off my motor this weekend. 1998 75 Force.

One of the bolts has and Allan key top to it. Can I use a normal allan key to remove it or is there a special type of allan key socket tool I need to use?

 

[Frank Acampora]

Re: Allan key bolt 1998 75 Force

Regular allen wrench BUT: I forget exactly, that may be metric. Merc mixed and matched metric and english fasteners in the late Force engines.

 

[emoney]

Re: Allan key bolt 1998 75 Force

Being in Australia, won't you be "lowering your powerhead"? (get it? The Land Down Under? Everything's upside-down? Buwahahahahaha.....I'm so funny)

 

[jerryjerry05]

Re: Allan key bolt 1998 75 Force

When you replace it,use stainless.

 

[TwoFish]

Re: Allan key bolt 1998 75 Force

Thanks Frank. It’s a bit of a “crapshoot” (I think this is a term you guys use) selecting the right tools for this motor. Metric in some places imperial in others. I just keep all the tools there and select the on that fits the best.

emoney , I enjoyed that. Made me laugh. I’ll make sure I tie the powerhead down so it doesn’t float off when I take the bolts out. It could also explain why I have so much trouble finding tools that I have just put down when working outside.

jerryjerry05, Stainless is a good idea. I was thinking of replacing the exhaust cover bolts with stainless but did not know whether they would be strong enough. The originals are grade 5 high tension. Have you heard of anyone using stainless on the exhaust bolts before?

Thanks for your help guys!

Cheers

TwoFish

 

[Frank Acampora]

Re: Allan key bolt 1998 75 Force

Just wait until september 21 when the Mayan calendar ends and the Earth's poles shift. Then, you guys will be up and the powerhead won't float off on you----easy!

 

[jerryjerry05]

Re: Allan key bolt 1998 75 Force

Yes I've seen stainless there.
They only have about 10# (I think)of tourqe on the screws.

There still will be some corrosion or reaction from dis-similar(?) metals.
But stainless should be easier to remove if you ever need to do this again.

 

[TwoFish]

Re: Allan key bolt 1998 75 Force

Thanks for the advice on the bolt. Most came out easily but a couple were a bit corroded.

As you can see I now have the block off of the motor and can work on the exhaust plate bolts much easier. 2 snapped already and another 10 are corroded solid. I will take my time on these. I have oxy/propane but it seems to be very harsh and direct. It heats up the bolts very easily if you leave the flame on them possibly softening them. When trying to heat up the metal around the bolts it still seems too harsh. I was wondering whether using a small propane torch would get better results as it would gradually heat up the metal. It may allow the heat to penetrate more. What would you suggest?

I looked back at the boat saw what was left of my outboard and I have to say I felt a bit nervous. I?ve never tackled anything on this scale before. If it wasn?t for the help on this forum I would not have considered doing this. It will be a good learning experience regardless of how things turn out.

Another thing that has helped is I have a wonderful wife who says that I should just go and buy another outboard and if I can?t fix this one. It certainly takes the pressure off a bit although it would make my Scottish ancestors spin in their graves.

I have grown attached to this outboard and would like to keep it a bit longer if possible. I would not be able to work on a new motor and I have been enjoying that part of owning a Force outboard very much.

I?m thinking that whilst I have the block out that I should pull the head off and check the bores for damage and water jackets for corrosion. I?m just a bit nervous about snapping more bolts. Is it something I should do seeing I have it apart this far? The compression is 140 on all cylinders so that hasn't been a problem.

 

[jerryjerry05]

Re: Allan key bolt 1998 75 Force

Too much heat can be a problem too.
I use a small propane torch.
The oxy/prop.can actually melt the aluminum and you will NEVER get them apart.

Remember,tap,spray,heat and repeat,again and again and again.
It will eventually come loose.

 

[TwoFish]

Re: Allan key bolt 1998 75 Force

Thanks for the encouragement jerryjerry05.

I plan on spending tomorrow attempting to remove the bolts. I will play some relaxing music and practice the Zen mindset of bolt removal.

All jokes aside it really does help to know you have done this before and I’m not wasting my time.

Cheers

TwoFish

 

[Jiggz]

Re: Allan key bolt 1998 75 Force

The head bolts are far more easier to work with, but not the exhaust. However, in your case with the head already off the lower unit, it should be mush easier. Use of heat should only be minimal and should be used in conjunction with penetrating oil.I know it sounds like you are trying to add fuel into a fire but with indirect heat, the oil can actually start penetrating as soon as the metal start to expand. Hence, loosening the bolt. During assembly I always use anti-seize for you'll never know when you will go through the same work again but at least you know it's not going to be as bad.

 

[TwoFish]

Re: Allan key bolt 1998 75 Force

Just letting you know how things finished up.

Snapped 8 bolts. 7 in the exhaust cover and 1 on the spacer plate next to the water tube. Got down to the last three and could not budge then so took the motor to someone who knew what he was doing. He snapped the last three but luckily just under the head of the bolts. He is going to try and weld nuts to the top of the studs and extract them that way. He says he has a good success rate with this method. Failing that he has some contacts in the engineering game that may be able to help.

It would have been nice if all the bolts came out but at least it is being sorted out now.

On the up side the casting in the exhaust area looks like new. No corrosion anywhere except the bolts. The motor has spent the last 4 years at least running in salt water. I'll take some photos when I get it back. Who said Force motors are made of junk metal and corrode badly? I very happy with that as it makes the decision clearer about whether to spend money repairing this motor.

I plan to replace the head gasket and have a look at things whilst the power head is off. It still has 140 psi in each cylinder so I’m not expecting any problems.

Thanks again for the help. I’ll keep you posted.

Cheers

TwoFish

 

[jerryjerry05]

Re: Allan key bolt 1998 75 Force

MY motors are going on 25 this year.
From time to time the head gaskets go.
When removing them,I'm amazed to see how good the insides look!!!