Trim sender screw thread size

[Scott06]

I'm in the process of replacing my trim sender on a 2003 alpha one gen 2, can't get the old screws off, suspect I will be drilling and tapping by the time I'm done. Anybody know the thread size ?

 

[kenny nunez]

The thread is 10/32. However unless you have a precision drill guide to keep the bit centered, good luck. You will probably do more damage. I used to just redrill new holes and tap them out. If the head of the screws are still present break the plastic away and try gently rotating the screws back and forth with vice grips and some heat. This worked a few times. Go back with Never Seize.

 

[Bt Doctur]

+1, remove the old senders by any means, try some heat and penetrating oil and visegrips, last option , cut them flush and drill and tap new holes in a new location

 

[San_Diego_SeaRay]

I just finished rebuilding a BRAVO transom assembly. One of the trim bolts you mention was not coming out. I finally ground the head off, removed the sending unit, and then tried to put vise grips on the remaining stud. Immediately broke off, leaving just a nub. So I tapped a two new holes and tapped the threads; one on either side of the nub (I ground the nub flush w. the gimbal ring). Went really smooth; no problems especially since you're tapping into aluminum. One thing I'd advise is to drill the hole that's just slightly smaller than the thread size. I think the more you ask the tap tool to do, the more likely you'll have problems. Good luck.