Slave solenoid terminal - 350 Mag 5.7 1986

[letsgogogadget]

Hey all,

Been searching and searching for a solution. I have a 1987 Mercruiser 350 5.7L and discovered the slave solenoid has gone bad. I removed the two bolts holding it in and disconnected the wires. The field coil screw was basically rusted on so bad it was like it was soldered in place. I tried leveraging it off but to no avail. Ended up grinding it off from the side the solenoid is on. Now I have this rusted/soldered looking piece on the +12VDC feed to the starter and I can't run a bolt through it to put the new solenoid on and no clue the best way to rig this.


Attached Photo for reference. Where a is (the wrench) was the bolt that was a rusted mess. Not allowing me to run a bolt through it for a new one.

If I have to put in a whole new starter, it will require me to pull the engine. Literally no room to get the bolts under start to release it.

 

[NHGuy]

First off welcome!

 

[NHGuy]

What about a reversible box ratchet? If they make them with flexible heads you might be able to get at the starter bolts from the side. What about those open end ratcheting wrenches. I wonder if they make them in a clawfoot style. Clawfoot type might be able to get around obstacles too. You will need the hex size for a 3/8 bolt. I think they are 5/8 but they could be 9/16.
I have changed a starter in the boat in a very tight spot. Ended up removing the bulkhead in front of my motor and reaching under the engine to turn the bolts. It was a lot of work, but I did save my summer cause I did not have gear to remove my engine at that time.
BTW if you buy a small format starter you may need shorter bolts or a stack of washers with the bolts you have.

but, to answer your question. Take off the end frame bolts and remove that, if there's room. Then you can fix the field coil connection where it goes into the frame. Or if it won't slide back far enough to remove you could still get at the bad spot better by rotating it to a better access angle.
Could you braise or bolt together the connection? Can you drill and tap where it needs to be? That sounds hard, like maybe not worth the effort hard.
You might just have to do it the way you are avoiding..removing the motor.
The big benefit to changing the whole starter is it's more trustworthy.

 

[Bt Doctur]

theres no pic, but if your asking about the solenoid mounted to the starter , remove the starter to repair it. you will never get it sealed otherwise.
photobucket pics ,please.the site is not letting them get thru yet.pulling the engine may not be necessary. can you remove the manifold for additional access?