Ok, you've seen this topic several times before. I've been struggling a few days and the thing won't budge. I've done this job over 20 years ago on a ~1970 Johnson 65, and I've been using pretty standard advice that you'll find on this and other online forums. I definitely realize this task can use all sorts of patience and persistence (with my personality, I have a bit of both), but I admit I am getting a bit discouraged :-( I'm not so sure I'm going to glean anything new, but maybe even some cheerleading and stories of other similar challenges will keep my head up.
BTW, I'm removing the flywheel after getting stranded with no spark (the kids were good about it and kept swimming
. Peak voltage testing of the stator (using a DVA peak-reading adapter) indicates only about 30 V: bad stator.
The flywheel nut removal was uneventful. I picked up an el-cheapo three-bolt puller from Autozone. After some initial use with the supplied bolts, one bolt stripped (I used the correct 5/16" 24 tpi). I may be guilty of not threading them in deep enough, they were in about 7 threads, but these bolts do not appear to be grade 8. I was a little concerned about damage to the flywheel threads, and would consider drilling and re-tapping with the next size fine thread (3/8-24), but after putting in new grade 8 bolts, the threads are holding nicely with the center bolt torqued down much more than with the original bolts.
I've been reluctant to give any more than light blows to the puller center bolt for fear of damaging the bottom crank bearing. I've also been reluctant to apply heat for fear of compromising the crank upper seal, bonding of the flywheel magnets, or the electronics (I suppose with the stator being removed, all that's left is the sensor).
On the first day, I had the puller center bolt torqued down to about 60-70 ft-lbs, and gave some minor blows with a standard 16 oz hammer. No luck, but not surprised. I let PB blaster soak in overnight.
The next day after work, I torqued down a bit more, and hit the puller center bolt little harder. Still no luck. OK, some are tougher than others... More PB blaster overnight. Also, I notice the puller is starting to deformed.
I'm now at the third or fourth day... I torqued the puller down to about 85 ft-lb, and it is visibly deformed. I even took the pressure off, it looks to have permanently deformed, as it bowed with no pressure on it. I have it back up to about 85 ft-lb.
After some reading iboat forums, I put a couple of wooden wedges between the crankcase and flywheel about 120 apart. I would have liked to have them more symmetric, but with the real-estate that I have, that's about the best I'll be able to do. My thought here is that in addition to providing additional "steady" force, this would also help reduce the impact of heavier blows to the center puller bolt.
Today, I dragged my upright 30 gal compressor to the marina (the boat is docked - I'm putting on entertainment for all the people with properly working boats) and wheeled it down 35 steps (the return trip was even more fun) so that I could use an impact wrench on the puller. I figure this shouldn't be nearly as damaging to the bearings since the impact is torsional rather than axial. No electric on this particular dock, so I just went with the 130 psi, 30 gal that was in the tank. Used it all up, still not budging. A kind soul saw my struggles and offered me his 7 amp electric impact wrench and power inverter... Still no luck.
After that, I hit the thing a bit harder (very reluctantly) with the blunt edge of an axe (estimate 5 lbs - I don't have a 32 oz hammer lying around). I'm not putting any muscle into it, just dropping under it's own weight about 6-8 inches. Reluctantly doing so... and hoping the wedges lessen any impact to the bearing. Still no motion. Also avoiding any harder blows.
I also reluctantly applied a bit of heat to the inner edge of the flywheel, not too much. Still no luck.
Tired, a bit discouraged. Let things cool a bit, applied more PB blaster with the thing under load and left.
Any advice, stories, cheerleading?!
For starters, I'm thinking about getting a better puller. This "OEM" branded one is flexing. Because of the arrangement for two- and three- bolt configurations, one leg appears to be deforming more. I'd much prefer a puller without "legs", like a hockey puck. It looks like the $150 evinrude puller is the best... Any recommendations on good pullers?
Even so, I'm not sure how much further I can load this thing up before I compromise the 5/16"-24 threads. Any suggestions here? Should I just continue to torque it down? 100 ft-lb? beyond? If I'm, correct, the bolt should fail before the threads?
Thank you!
Paul
BTW, I'm removing the flywheel after getting stranded with no spark (the kids were good about it and kept swimming
. Peak voltage testing of the stator (using a DVA peak-reading adapter) indicates only about 30 V: bad stator.The flywheel nut removal was uneventful. I picked up an el-cheapo three-bolt puller from Autozone. After some initial use with the supplied bolts, one bolt stripped (I used the correct 5/16" 24 tpi). I may be guilty of not threading them in deep enough, they were in about 7 threads, but these bolts do not appear to be grade 8. I was a little concerned about damage to the flywheel threads, and would consider drilling and re-tapping with the next size fine thread (3/8-24), but after putting in new grade 8 bolts, the threads are holding nicely with the center bolt torqued down much more than with the original bolts.
I've been reluctant to give any more than light blows to the puller center bolt for fear of damaging the bottom crank bearing. I've also been reluctant to apply heat for fear of compromising the crank upper seal, bonding of the flywheel magnets, or the electronics (I suppose with the stator being removed, all that's left is the sensor).
On the first day, I had the puller center bolt torqued down to about 60-70 ft-lbs, and gave some minor blows with a standard 16 oz hammer. No luck, but not surprised. I let PB blaster soak in overnight.
The next day after work, I torqued down a bit more, and hit the puller center bolt little harder. Still no luck. OK, some are tougher than others... More PB blaster overnight. Also, I notice the puller is starting to deformed.
I'm now at the third or fourth day... I torqued the puller down to about 85 ft-lb, and it is visibly deformed. I even took the pressure off, it looks to have permanently deformed, as it bowed with no pressure on it. I have it back up to about 85 ft-lb.
After some reading iboat forums, I put a couple of wooden wedges between the crankcase and flywheel about 120 apart. I would have liked to have them more symmetric, but with the real-estate that I have, that's about the best I'll be able to do. My thought here is that in addition to providing additional "steady" force, this would also help reduce the impact of heavier blows to the center puller bolt.
Today, I dragged my upright 30 gal compressor to the marina (the boat is docked - I'm putting on entertainment for all the people with properly working boats) and wheeled it down 35 steps (the return trip was even more fun) so that I could use an impact wrench on the puller. I figure this shouldn't be nearly as damaging to the bearings since the impact is torsional rather than axial. No electric on this particular dock, so I just went with the 130 psi, 30 gal that was in the tank. Used it all up, still not budging. A kind soul saw my struggles and offered me his 7 amp electric impact wrench and power inverter... Still no luck.
After that, I hit the thing a bit harder (very reluctantly) with the blunt edge of an axe (estimate 5 lbs - I don't have a 32 oz hammer lying around). I'm not putting any muscle into it, just dropping under it's own weight about 6-8 inches. Reluctantly doing so... and hoping the wedges lessen any impact to the bearing. Still no motion. Also avoiding any harder blows.
I also reluctantly applied a bit of heat to the inner edge of the flywheel, not too much. Still no luck.
Tired, a bit discouraged. Let things cool a bit, applied more PB blaster with the thing under load and left.
Any advice, stories, cheerleading?!
For starters, I'm thinking about getting a better puller. This "OEM" branded one is flexing. Because of the arrangement for two- and three- bolt configurations, one leg appears to be deforming more. I'd much prefer a puller without "legs", like a hockey puck. It looks like the $150 evinrude puller is the best... Any recommendations on good pullers?
Even so, I'm not sure how much further I can load this thing up before I compromise the 5/16"-24 threads. Any suggestions here? Should I just continue to torque it down? 100 ft-lb? beyond? If I'm, correct, the bolt should fail before the threads?
Thank you!
Paul
