Stuck bolt on '78 35hp johnson

[bluefishing]

Hello,

Due to an impeller failure, my powerhead overheated and I blew a head gasket and possibly the gasket around the exhaust cover. The bolts came off the head just fine. However, one bolt on the exhaust cover, (part 23, lower left hand corner bolt, http://shop2.evinrude.com/Index.aspx?s1=lpq2emo2g0i5rmmgfnnpco57f0&catalog_id=0&siteid=1[/URL ) is stuck. Can anyone suggest the best way to get this bolt out?

Thanks

 

[ONERCBOATER]

Re: Stuck bolt on '78 35hp johnson

well i can tell you what i did with mine, your welcome to consider it but i don't want to get blamed if you break something.

what i did was clean all around the bolts with carb cleaner (brake cleaner works too) in the spray can, please remember i wasnt worried about the paint, i just wanted to make sure that any easily removable crud was gone. next I used Breakfree (everyone has their favorite penetrating oil, my choice is from the results in my other big hobby gunsmithing). then I walked away and came back the next day. Some of the stuck bolts released, others didn't so..... I used a bit more breakfree and waited another day then tried to tighten them a bit, then loosen them.... all but one released at this point.

I was getting frustrated at this point and decided that i would get just a lil bit more extreme, I sprayed it with breakfree again and hit it lightly with a map gas torch.... no joy still stuck, so i took out an impact wrench and put it on lightest setting and loosened then tightended and loosened it took a good 10 min of gently working on it. I had scribed it so that i could see it it moved, when it loosened a bit i sprayed it again, then came back 20 min later and it came out like it was never stuck.

you have to understand that at this point I was resigned to break it off, drill it out tap it and helicoil it if needed, if you choose to use an impact gun be prepared to strip threads or break bolts.

I hope some one has a better suggestion for you than my answer, as I will be right there reading it with you

just noted that the machinist has some information that may be of value to you on this subject.

http://www.sschapterpsa.com/ramblings/Johnson 9.9_15.htm

look about 3/4 of the way down the page dealing with broken off bolts.

Sean