Struggling with powerhead removal

[DamianJP]

Hey guys

Ive done some searching in these forums and also see other people having trouble with removing the power head. Its a 1977 55hp Evinrude and its giving me problems. I made a makeshift A frame with a chain pulley and its not poping off. I tried to heat the seam between the adapter plate and head, also sprayed penetrating stuff into the seam. Also heated the back aft nut stud and solvent too.

I have all 8 bolts and 1 aft nut off. Also have the Lower unit dropped.The chain pulley is lifting up hard on the power head, its crazy how it not coming off. This has got to be the original gasket and seal. 30 years of heating up and cooling down.

Im getting me very pissed off , its driving me nuts. Multiple rounds of heat and penetrating solvent and taps by a wood piece and small sledge while the pressure of the chain pulley too.

Also I had the adapter plate bolts out of the back part and the part effortlessly came up a small bit with no problem. This top powerhead gasket is on like it was permanently put on.

Mabey someone has any info that will help me get it off.


Thanks,
DamianJP

 

[ONERCBOATER]

Re: Struggling with powerhead removal

yes it can be done it isnt easy.
1st make very very very very very very very very very sure that you have every possible fastener removed....one lil bolt or nut missed and the next part will screw you up.
put a very sharp putty knife or scraper at the seem.... tap it in..... you should be able to hit it from opposite diagonal corners and have it pop free.
Kinda funny how hard they are to get off, I spent 5 days on one before i found out how and that was for a cute lil 15hp.
the trick is.... Sharp, gentle, dont go in too deep...the reason for putty knife or scraper is they are less likely to cause damage. once i figured out how to do it,,,i have happily used a very sharpened standard screwdriver....and been very gentle. it's the wedging action your looking for.... preferably as gentle as possible. the plastic wedges used for lock out kits might work as well.... i'll likely try that out next time i have one to do.
others know far more than me,,, if they tell you not to do this... i would say listen to them. but that is the way i do it.

Sean

 

[ONERCBOATER]

Re: Struggling with powerhead removal

please note I haven't actually worked on that model engine, but it has worked for both merc and johnnys that i have. prudence and gentleness are the key words.

Sean

 

[DamianJP]

Re: Struggling with powerhead removal

Hey ONERCBOATER

Well Im gonna head down there in abit 'armed' with your tactic and get in off. Gonna start with something plastic first and see if I can get it, if not I'll bring an array of stuff to try but I'll be as 'gental' as I can.

Should I try and do this while the powerhead is under pressure from the chain hoist?

Hopefully Ill be able to come home with a 55hp powerhead and slowly start to dissemble it and start some foward motion in this project. Man usually Iv'e have alot of patience and haven't cursed alot while Im working on stuff but this was wearing me thin.


Thank you again OnercBoater
DamianJP

 

[ONERCBOATER]

Re: Struggling with powerhead removal

most times the tension was unneeded. the wedging action did the job, if it is suspended...err might release suddenly and be rather surprising... make sure you got a way to hold things up if you gonna do that one.....
and as i said, make sure every single fastener is off....... triple check the schematic/parts breakdown.

Sean

 

[ONERCBOATER]

Re: Struggling with powerhead removal

oh and pick a spot that isnt a boss for a bolt, or an ear....essentially something that doesnt look like it gonna break off.

 

[DamianJP]

Re: Struggling with powerhead removal

Hey Sean

Got it off,Worked awesome Thank you. But I did break the already broken bolt shaft and have less of the shaft to get vise grips on the bolt shaft to get it out.

Now I have a couple of threads. Ive never had luck getting these things out so Im abit worried. Mabey I can get my buddy to weld a nut on the couple of threads and back whats left of the stud.

Can I bring it to a machine shop and have them extract it %100?

Whats my options to get it out and if it doesn't come out?

Now I have about 8-10 bolts to mess with on the exhaust cover. Hope they all come out.



Thanks,
DamianJP

 

[tx1961whaler]

Re: Struggling with powerhead removal

Welding a nut on is the best choice.
Machine shop could easily do it.
Drilling out with a left-handed twist cobalt bit works, but you have to be very careful to center it.
EZ-out extractors will just break off, leaving a huge mess.

 

[DamianJP]

Re: Struggling with powerhead removal

Hey guys

Almost done with messing with salty bolts and such. 4 last bolts on the lower part of the mid section for the lower rubber mount housings. And this 'damn' stud extraction.

Yup gonna have a buddy weld a nut on and try that first. I "hate" using the EZ-outs or left hand drill thingys because I rush them and make stuff worse. My friend mike is awesome and Iv'e seen him extract stuff before. My only saving grace is that it was already loosened and was coming out and then the bolt stoppped turning (Prolly because the crap coming out of the threads bunched up and made it hard to turn, then snapping the bolt) so hopefully the stud/remainder of the bolt comes out and the other 4 bolts come out good and stuff should be down hill from there.

Im gonna start another thread dealing with replacing rings and bearings , so check it out please, Iv'e never done this before so I need all the help I can get.

Iv'e got the head back at my humble shop and gonna play with it tonight and do what I can and hit the broken bolt and other 4 bolts tomorrow.


Thanks guys A BUNCH!,
DamianJP