Broken lower unit bolt 1988 80hp

[Dallenx]

I'll make a super long story kind of short.
My console mount shifter with trim/tilt broke internally. I thought the shift cable had frozen. While installing a used 'newer' model shifter I found that the cable was ok. I then found that the motor won't shift. Fearing the lower unit was messed up, I took it off. The unit seems fine but the shift rod going down to the lower unit was frozen. I found that the rod had backed its way up and was jammed against the head of the motor.

I got the rod back down and I'll need to see if the clips are missing.

Here's the bad part......I broke the two port side bolts on the lower unit. They were seized and broke off nearly flush. The starboard side bolts came out ok but are showing serious corrosion.

Question...what size / type are these bolts? I can get them measured but I just want to be sure. Also, what material are they made of?

Thanks!

 

[achris]

Re: Broken lower unit bolt 1988 80hp

Not sure of the size, but Merc stock them. They should be UNC so any good nut and bolt shop should be able to help you. Merc only want about 2 and a half bucks each for them. I'd get them from Merc, that way you know you have the right ones. Part number is 10-40003 80. They are stainless steel, so good luck on getting the old one out.

And there are no clips on the shift shaft. It stays down because of gravity.

Chris.......

 

[Dallenx]

Re: Broken lower unit bolt 1988 80hp

I stopped by the local shop and they had 4 new bolts. I also picked up a cobalt drill and extractor set. I thought my luck was turning.
One of the bolts is nearly drilled through now with the largest bit I have but the spiral extractor keeps slipping. The darn bolt is stuck hard. I had to stop due to loss of daylight. I wish that I could turn the engine upside down and spray some break-free on to that bolt so that it could soak down in.

 

[Chris1956]

Re: Broken lower unit bolt 1988 80hp

try heating the bolt and then spraying with a good penetrating oil. Maybe you will get lucky and as the bolt cools, it will suck the oil in and loosen up.