broken starter bolts!

[makinc80]

i have a 1996 3.0lx mercruiser with an alpha 1 gen 2 drive in an 18ft stingray. i attempted to start it at the dock and i thought the batt. was dead. after further investigation i found the starter lying on the floor! i figured the bolts backed out but to my dismay they snapped inside the block! what do i do now!!!! i figure a right angle drill and an ez out is my only option they are approve 1/8 - 1/4 inch inside the block (guess there is a shoulder). i really don't want to pull the motoe considering i am gonna sell her and i really don't wanna sink the extra time, and tools into her! there shouldn't be too much pressure on them. anyone tackle this type of problem before. i am very discouraged! boat ran perfect all summer. i was just gonna sell her to upgrade to a 24ft'er. thanks in advance. at least broken at the dock is better than broken in the middle of the bay! she was always good to me!

 

[daydreamer1252]

Re: broken starter bolts!

Have you ever mentioned selling her or getting another boat while in her company? ....I'm just saying.......

 

[cich69]

Re: broken starter bolts!

I have run into this same problem. I went to my local specialty bolt shop to buy an easy-out and a drill bit. They sold me a left handed drill bit (one that does the drilling with the drill in reverse), an easy-out and two new bolts. I found that using the left handed bit with my right angle cordless drill was all it took to remove the broken parts of the bolt. After drilling 1/4-3/8" into the bolts they spun right out with the drill bit, didn't even need the easy out!

But, what you really need to figure out is why the bolts broke in the first place or you will have the same problem again. I'd guess most likely water in the cylinders hydrolocked your engine. Try pulling the spark plugs and turning the engine over a full rotation to check for water.

 

[dollarten]

Re: broken starter bolts!

I have run into this same problem. I went to my local specialty bolt shop to buy an easy-out and a drill bit. They sold me a left handed drill bit (one that does the drilling with the drill in reverse), an easy-out and two new bolts. I found that using the left handed bit with my right angle cordless drill was all it took to remove the broken parts of the bolt. After drilling 1/4-3/8" into the bolts they spun right out with the drill bit, didn't even need the easy out!

But, what you really need to figure out is why the bolts broke in the first place or you will have the same problem again. I'd guess most likely water in the cylinders hydrolocked your engine. Try pulling the spark plugs and turning the engine over a full rotation to check for water.

If you had the old GM or Delco starter on you 3.0 ,this was not too uncommon . These engines had an additional support bracket attached to the stater the to the block to reduce the viberations that got transmitted to the starter . Sometimes the brackets come loose or don't get reinstalled for whatever reason . This leaves the starter hanging on with two 3/8 bolts and acting like a tuning fork with the once additional bracket missing to dampen the engine viberations . The four cylinder engines are not like V8's and give quite a bit of viberation . This viberation finally causes the bolts to snap one at a time until the starter falls off .. Mecruiser remidied this by going to the gear reduction starter which is about 65% light and is not such a strain for the starter bolts These starter bolts are not bottomed to the threads and are free to turn once the starter in no longer there . Good luck

 

[Volphin]

Re: broken starter bolts!

Before you start drilling, squirt a good amount (more is better) of PB Blaster or WD40 on those embedded bolts. Let sit overnight. THEN go for it. Hint: Sometimes tapping the broken off bolt with a punch and ball peen hammer speeds the oil penetration.

V

 

[makinc80]

Re: broken starter bolts!

thanks for the help everyone!!!! i have no shore power at my slip so a right angle drill, drill bits, ez out and 10000watt generator did the trick! didn't even need the ez out! great info as always....luck shined upon me and i had the job done in 45 minutes. went through the top for the outside and up the middle for the inside. worked like a charm! again....THANKS !!!!!

 

[makinc80]

Re: broken starter bolts!

JST A note for duy'ers.....i took the old broken bolt and drilled a hole in the center up the middle...then ground the shoulder down to fit in the hole and shortened the shoulder to approx. 1/8" i taped the heck out of the drill bit to keep the new jig close to the top of the bit until i applied pressure and fit it in the hole. assisted me in drilling true and not messing up the threads. hope this helps. all u need is a grinder and the drill.......worked for me!