Johnson 40 hp powerhead bolt oops

[maineiac5586]

I'm working on a 2001 Johnson 40 hp 2 stroke 2 cylinder. Swapping powerheafs. One of the powerhead bolts was seized and snapped off. I was able to drill out the broken remains and retapped the hole. Problem is I wasn't straight on so now the bolt is angled so bad that the new bolt doesn't engage in the engine block thread hole (when passing the bolt through the hole in the mid section to secure powerhead.) The bolt issue is located on the port side of the engine second one back from the front side. There is a small rectangular water passage hole fairly close to the broken bolt. There are 3 other bolts on that side of the engine (all other bolt holes ok) I was thinking of installing the powerhead with this problem bolt missing (maybe skim some rtv on both sides of the powerhead gasket? Any thoughts?. I know the right way would be to fill the hole and retap but I don't have the desire to do that. Thanks

 

[saltchuckmatt]

I'm working on a 2001 Johnson 40 hp 2 stroke 2 cylinder. Swapping powerheafs. One of the powerhead bolts was seized and snapped off. I was able to drill out the broken remains and retapped the hole. Problem is I wasn't straight on so now the bolt is angled so bad that the new bolt doesn't engage in the engine block thread hole (when passing the bolt through the hole in the mid section to secure powerhead.) The bolt issue is located on the port side of the engine second one back from the front side. There is a small rectangular water passage hole fairly close to the broken bolt. There are 3 other bolts on that side of the engine (all other bolt holes ok) I was thinking of installing the powerhead with this problem bolt missing (maybe skim some rtv on both sides of the powerhead gasket? Any thoughts?. I know the right way would be to fill the hole and retap but I don't have the desire to do that. Thanks

I believe it won't work. Broken bolts in outboards is the curse. If you have the means fill it and start again.

 

[jimmbo]

Any thoughts?. I know the right way would be to fill the hole and retap but I don't have the desire to do that. Thanks

Either fix it correctly, or repeatedly fix it incorrectly. I guess it all depends on how much time you are willing to spend