Any tips on pulling a powerhead off?

[woodsyfeller]

I have a 115hp L6 Mercury @1979 started up motor the other day getting it ready for the season and noticed it was leaking out a hole that is in the exhaust cover. So I need to pull power head off to get to all the bolts on the exhaust cover. Got all items disconnected and have an engine lift to pull power head . It doesn't budge sprayed some penetrating oil on it and called it a night.
I may drop the lower end just to make sure it isn't frozen onto drive shaft. It should be good I lubed it up pretty well last year when I replaced the impeller.

Was hoping to maybe hear of some mechanic tricks or ideas to make pulling powerhead off easier.

 

[mercurymang]

Re: Any tips on pulling a powerhead off?

You have to pull the powerhead to get the exhaust cover off? Didn't know that. Looking at the diagram online, there appear to be 8 bolts/nuts holding it to the tower. Are they all off? Are you sure you have to pull the powerhead to get the exhaust cover off?

 

[woodsyfeller]

Re: Any tips on pulling a powerhead off?

yes since 4 of the bolts are below the lower cowl cant remove the lower cowl. Hence have to remove the powerhead .You can barely change the number 6 sparkplug with that darn cowl in the way. Yes the nuts are all off the bottom . I'm guessing its never been removed before and the motor has been in the saltwater at least 1 season.

 

[frankenmerc]

Re: Any tips on pulling a powerhead off?

Woodsyfeller
What I have done in your situation is put a nut back on the powerhead stud on each side about half to full thread and use a wrench or something to pry up
Between the nut and the part under it on the mid section, it has worked for me many times.
good luck.

 

[woodsyfeller]

Re: Any tips on pulling a powerhead off?

that's what I was think or something similar , I was going to put the nuts back on enough until the stud just about passes through the nut, then stack some washers under each nut until they just touch and unthread the nuts hopefully pushing the power head up until it breaks free. I will respond back maybe take a pic or 2 to explain it better tomorrow after I give it a try.

 

[merc850]

Re: Any tips on pulling a powerhead off?

The gasket is probably holding it together.
I had to do the same thing and to get it off I lightly hammered an eating knife ('cause I didn't have a gasket scraper) into the gasket all the way around while pulling up on the powerhead, the gasket is available from Mercury so don't worry about wrecking it.

 

[Chris1956]

Re: Any tips on pulling a powerhead off?

OK, Did you get the two bolts in the front, near the steering arm? Drop the gearcase as well. It will be much easier to install the powerhead, with it off. Leave the hoist loose and push on the top of the block, from the side. They will usually break loose like that.

 

[woodsyfeller]

Re: Any tips on pulling a powerhead off?

Stacking the washers did the trick , new problem is I busted 7 bolts out of the 21 on the cover. I got 4 out tonight with a torch and vice grips had to give up on the last 3 because it was getting late hit em with more pb blaster and will try again tomorrow.

 

[mercurymang]

Re: Any tips on pulling a powerhead off?

Been there. See my thread on this. http://forums.iboats.com/mercury-mariner-outboards/advice-wanted-583988.html

 

[Chris1956]

Re: Any tips on pulling a powerhead off?

Heat the bolts with the torch. Now remove the heat and spray 'em good. As they cool, they can suck in the oil and loosen up. Repeat a few times, and say a prayer to your deity, if you have one.

 

[emckelvy]

Re: Any tips on pulling a powerhead off?

Drill out the bolt heads. When the covers are off, you'll have more bolt to grip. The best repair on the busted bolts is to drill out the broken stainless bolt completely, and replace with Heli-coils.

It's almost impossible to tap out stainless bolts when they're seized in aluminum. The stainless remnants will jam the tap and you run the risk of tearing out whatever aluminum threads are left, or breaking-off the tap in the block. Which is an even worse repair!

You can, however, cleanly and completely drill out the bolt (with proper-hardness drill bits), and then it's a simple matter of tapping out the block with a Heli-coil tap and install the stainless insert. The repair will be stronger than new, and if you apply a thin coating of Permatex #3 Aviation-type non-hardening gasket dressing to the bolt threads, they'll never seize again.

HTH & G'luck with the repair.........ed

 

[Chris1956]

Re: Any tips on pulling a powerhead off?

Normally the water jacket cover bolts are grade 5 or 7 steel. So they are drillable. If you do need to drill them out, try to get some left handed drills, made of cobalt. Center punch them and use a drill press, if you can get one. A lot of times, the lefty drills will cause the bolt to work it's way out.