Broken water jacket cover bolt

[Plainsman]

I broke a blot that holds the water jacket cover on, I am sure more will break. So do I just keep using the socket or is there a tool that I can get that might reduce the number of breaks? The one that broke was white on the threads, I am asuming due to water, which made it brittle.

Then use a tap and die to get the broken ones out, correct?

TIA,
Eric

 

[Laddies]

Re: Broken water jacket cover bolt

Eric, tap the heads of each bolt with a hammer before trying it, if possible use heat and real care those bolts are stainless and do not drill easily

 

[Silvertip]

Re: Broken water jacket cover bolt

A tap & die are not used to extract bolts. Taps are used to cut threads in an untapped hole. Dies are used to cut threads on a unthreaded rod. I think the tool you are thinking about is called an "Easy Out".

 

[Plainsman]

Re: Broken water jacket cover bolt

Thanks Bob, I'll give it a shot. And thanks Silver for the correction.

 

[Chris1956]

Re: Broken water jacket cover bolt

Ed, All the water cover bolts on my '76 1500 Merc are grade 7 or 9 steel. The bolts on the cylinder head water jacket thread into captive nuts in on the block. If these break, you can replace the nuts on some years. If the nuts are not replaceable, you can drill through the block casting and add additional nuts on the back side.

If you are working on the exhaust port water jacket cover, use heat, penetrating oil and an impact driver, and gently coax the bolts out. If you heat the bolts, and spray them with the oil (watch out for fire), and then gently use the impact driver, you should get out the majority without breaking them. I broke only four bolts on the inner water jacket cover. All the bolts on the outer cover came out without incident.

 

[Plainsman]

Re: Broken water jacket cover bolt

Thanks Chris

 

[Plainsman]

Re: Broken water jacket cover bolt

Well I tried all of the above and most of them broke only got 5 out and they were very rusted. Now I have to try and drill them out I guess. I'm afraid of the drill getting into the alum cover.

Any idea's on how to get them out with out drilling?

 

[Chris1956]

Re: Broken water jacket cover bolt

See if there is a void in the block, behind the end of the bolts. If so, you can drill straight through and replace the bolts with bolts and nuts. Also, take off the water jacket cover and try a visegrip on the bolt remains.

My '73 850 actually has nuts that were replaceable. If not, you will have to drill and tap all the broken bolts.

 

[Plainsman]

Re: Broken water jacket cover bolt

Chris,
The cover won't come off. It looks like the gasket failed around the whole cover, I see white deposits on it. Would heat loosen this up?

 

[Laddies]

Re: Broken water jacket cover bolt

Eric, those aren't S/S bolt so your in luck when you drill them (some luck Huh) Ussually tapping on the sides of the plate will loosen them, don't pry as they spring easily and won't seal right. I have a friend who arc welds a piece of angle iron or nut to the stubs to remove them, I am not that good he says it's the easiest way, I still drill and use a easy out on them. I only use the easy outs that look like torx bits, in fact I have even used bits a couple times. After drilling I seat the bit, remove it and heat the bolt with a aclene torch, then replace the bit and try to remove the broken piece. For Gods sake and yours don't break the easy out. If you can't get it out and don't have a broken easy out in the hole you can drill them out and install heli coils in the holes--Bob

 

[Plainsman]

Re: Broken water jacket cover bolt

Thanks Bob, I will try tonight. Is there a recommended type of drill bit for this? Start out with a smaller bit and work my way up?

 

[Laddies]

Re: Broken water jacket cover bolt

I always center punch the bolt, use only the best drills and easy outs and I always start with a smaller drill as it give me a chance ot correct the center if I miss it the first time (just drill enough to ck center and it's easy to angle it back) Good Luck - Bob

 

[gungalunge]

Re: Broken water jacket cover bolt

Those bolts have nuts on the bottom ,that go right underneath . I suggest like i did on my rebuild . remove that top water jacket . once you get the whole top cover off . take a dremmel cut wheel . shave the boltls off. they simply fall out . from the bottom . you will need a new gasket .use some indian head shallac .get all new bolts and nuts . and some locktite .

 

[Plainsman]

Re: Broken water jacket cover bolt

Thanks gung, I am going to try and get the cover off once it warms up again.

 

[Plainsman]

Re: Broken water jacket cover bolt

$285 for 10 holes at the machine shop. I think it was reasonable.

 

[DHPMARINE]

Re: Broken water jacket cover bolt

Good going.Actually $28.50 each is a good chunk of money per hole,but decent for a machine shop.
They have to stay in business.As we all do.

My shop would probably have sent it out also,because trying to remove 10 out of 10 IS a machine shop job.

DHP

 

[Plainsman]

Re: Broken water jacket cover bolt

Removed to old gasket from the cover and it is lightly pitted in areas, is this a concern or will the gasket compensate for this?

 

[Laddies]

Re: Broken water jacket cover bolt

Eric, if they are pitted I use a little #2 prematex to help the seal--Bob

 

[Plainsman]

Re: Broken water jacket cover bolt

Thanks Bob!