Another Stuck Powerhead, Need advice

[RKwood]

While in the process of removing powerhead on '84 1.6l Sea Drive, snapped off the head of one of the 6 long mounting bolts. It flush with surface of midsection, with a little bend to it. <br /><br />I have lwr unit removed, by needless to say powerhead won't budge. <br /><br />What should I do next?<br /><br />Any advice would be appreciated.<br /><br />RK

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

For what it's worth the stuck one is on the front port side.

 

[Hooty]

Re: Another Stuck Powerhead, Need advice

Is it the slight bend or corrosion that's keeping the p/h from moving up over the busted bolt? If it's corrosion, put some tension (pull) on the p/h and douche around the busted bolt with PB Blaster or Kroil (no WD40) and let it sit for a while. If it's the bent bolt, we'll have to study on that a while.<br /><br />c/6<br /><br />Hooty

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

I think right now it's the corrosion thats got her stuck. I do think the slight bend on the bolt (as a result of the head twisitng off), may hang things up along the way.<br /><br />I have the lifting eye, but we still need to rig something up to "hoist" from for contsant pressure.<br /><br />Thoughts in desperation........how about a little heat on the upper mid section where the bolts go through. Then hit remaining bolt shaft with a drift, while powerhead is under constant pressure?<br /><br />Will a penerating oil (PB, Kroil, etc) go up the bolt shaft?<br /><br />RK

 

[Hooty]

Re: Another Stuck Powerhead, Need advice

Maybe I misunderstood. I thought the head of the bolt (top) twisted off and the penetrating oil was going to soak down. If the bottom is what twisted off, we may have to change the plan.<br /><br />c/6<br /><br />Hooty

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

Hooty,<br /><br />For the most part I think you have it.<br /><br />Regarding won't budge, I can't even get this thing to break free from the base itself, not even a little to dump PB down the broken bolt shaft.<br /><br />The bolt head did twist off. This has left almost all of the bolt shaft in the upper midsection, with most of threaded portion still in the head also. <br /><br />I think we did get a couple of turns before it broke, so if we could just get the head off I'm pretty sure the broken bolt shaft will come out of the head easily. <br /><br />I am also somewhat fearful the bolt shaft might be bent, along with the "kink" at the bottom from twisting bolt head off. Almost all the other powerhead fastners on the port side where loose. I had pretty severe exhaust leaks at the base and was intending on changing base gasket and re-torqueing.<br /><br />It all seemed good in theroy! Now if I can just find that post with the link for the magic dust to remove broken bolts!<br /><br />Last but not least I'm not trying to compete with Outrage for attention on getting his powerhead unstuck! <br /><br />Please Heeeeeeeeeeeeeeeeeeeeeeeeeeeeeelp!<br /><br />RK

 

[Solittle]

Re: Another Stuck Powerhead, Need advice

Take it to a machine shop. It should not be expensive - they won't screw it up as they do that stuff for a living. It will save you much anguish.

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

So Little, I'm sure that's sound advice. <br /><br />The twist here is that we don't have a trailer, and nothing that would tow it anyway. <br /><br />I hope to get a another shoot at things tomorrow after work.<br /><br />RK

 

[Hooty]

Re: Another Stuck Powerhead, Need advice

Would it be possible for you to post a foto so we can see what you're up against?<br /><br />c/6<br /><br />Hooty

 

[Chinewalker]

Re: Another Stuck Powerhead, Need advice

In addition to the six bolts, isn't there a stud with a nut on it in the rear of the motor, under the exhaust cover plate?<br />- Scott

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

I beleive I have all the nuts and bolts out. Actually there are two studs under the exhaust plate. One study had totally worked loose, the other was intact but nut was gone. I also got the nut and bolt on each side in the front bottom as well as the two bolts on the rubber mounts.<br /><br />I hope to get to the boat after work today, and take some pics.

 

[jim dozier]

Re: Another Stuck Powerhead, Need advice

Sounds like you have read Outrages predicament also. I've pretty much put in my 2 cents worth there. If its not already flush with the lip of the midsection, get a dremel tool with a rotary blade and cut the broken bolt shaft even with the casting. This will remove as much of the bend as possible and then with the motor hanging on a lift start tapping with a drift the same size as the bolt shaft. I had an identical situation with my motor and through much bad language and extreme perserverance was able to, micron by micron, move the bolt (and the attached powerhead) up about 1/4 inch so that I could saw throught it between the powerhead and the casting. The problem is that the corrosion gets a surprisingly good grip on the long shaft and the more you pound on it the more it mushrooms in the casting so that it wedges in there. But you only need about 1/4 to get a rotary blade in there and cut it off. It easy to pound it back down in the opposite direction when the power head is off.<br /><br />This should be done after you have heated the bolt red hot and cooled down several times and let some penetrating oil sit on it for a day. Problem is that the oil doesn't get very far and its a long shaft. Use the heat on the bolt not the casting.

 

[getyouten]

Re: Another Stuck Powerhead, Need advice

2 ways to go about it, the way I like to do it, raise the powerhead and wedging it up on the side that is loose until the threads give way on the frozen bolt, then put a heli-coil in it. the other way is to cut the bolt at the powerhead gasket ( problem there is damage to the powerhead and the exhaust adapter and also hard to get to) did one last week and it took about 15 min. the way I like to do it.

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

Well, success at last, sort of............<br /><br />I can't say it popped off like I would have wanted, or expected for that matter, but it's off.<br /><br />I think Getyouten had the clearest crystall ball!<br /><br />We rigged up a come-along to the rafters of this pole barn we were in. We then ground "kinked" portion of the bolt flush with housing. Last but not least a good dose of PB<br /><br />With that done the hoisting began. With a few cranks and a whack or two the majority of the powerhead tilted off. The one broken bolt held on pretty good. <br /><br />We continued to hoist, beat, and blast with PB.<br /><br />Then, as quickly as the bolt head snapped off, the powerhead popped up. Suprisingly, bolt didn't pull through, but stripped out of the block. <br /><br />Even with that I'm happy it's off!!<br /><br />The other suprise was that the front midsection rubber iso-mount to lwr cvr(?) was cracked at the webing to the mount. I don't think our "hoisting" had anything to do with it,stuck bolt was on the same side but on the front, but who knows. Will be looking for a local welder that travels for that one.<br /><br />Any objections to heli-coil? I guess the alternative is to weld and tap. I guess having never having done either, heli-coil seems DIY, any durability concerns?<br /><br />I have a few pictures, could someone provide a site to post on.<br /><br />Rob K.

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

Well, success at last, sort of............<br /><br />I can't say it popped off like I would have wanted, or expected for that matter, but it's off.<br /><br />I think Getyouten had the clearest crystall ball!<br /><br />We rigged up a come-along to the rafters of this pole barn we were in. We then ground "kinked" portion of the bolt flush with housing. Last but not least a good dose of PB<br /><br />With that done the hoisting began. With a few cranks and a whack or two the majority of the powerhead tilted off. The one broken bolt held on pretty good. <br /><br />We continued to hoist, beat, and blast with PB.<br /><br />Then, as quickly as the bolt head snapped off, the powerhead popped up. Suprisingly, bolt didn't pull through, but stripped out of the block. <br /><br />Even with that I'm happy it's off!!<br /><br />The other suprise was that the front midsection rubber iso-mount to lwr cvr(?) was cracked at the webing to the mount. I don't think our "hoisting" had anything to do with it,stuck bolt was on the same side but on the front, but who knows. Will be looking for a local welder that travels for that one.<br /><br />Any objections to heli-coil? I guess the alternative is to weld and tap. I guess having never having done either, heli-coil seems DIY, any durability concerns?<br /><br />I have a few pictures, could someone provide a site to post on.<br /><br />Thanks for everyones help, could not have done it without this board!!!!!!!!!!!<br /><br />Rob K.

 

[jim dozier]

Re: Another Stuck Powerhead, Need advice

As long as there is sufficient metal around the bolt hole a helicoil works well and is realtively easy to install. Just take care to keep the oversize bit centered when you drill out the old threads. If you don't have some kind of template, it helps to use several graduated drill bits till you get to the right size.

 

[RKwood]

Re: Another Stuck Powerhead, Need advice

Can someone provide helicoil size for mounting bolt hole in block?

 

[jim dozier]

Re: Another Stuck Powerhead, Need advice

Take one of the other similar bolts you removed to a NAPA auto parts store. They can tell you the size and thread and point you to the helicoil. They just go by bolt size i.e. 3/8 inch fine thread. The helicoil package comes with the correct tap spare coils and will tell you what drill bit to use.

 

[Outrage 19]

Re: Another Stuck Powerhead, Need advice

Hi RKwood,<br /><br />I’m glad to see you overcame your obstacle. This weekend will be my third attempt at trying to pull my power head. Best wishes to ya.