Trim sender bolt broke

[Donzi GT250]

I was adjusting the trim sender on my 1989 5.7 Cobra drive today.
The lower bolt broke off so we drill it out OK and in the process of running the tap in the hole the tap also broke off also.
So now I have a broken tap in the hole and no way to get it out as the tap is too hard to drill.
I have the sender fastened to the drive with the top bolt and it works for now but I don't think it will hold without the lower bolt.
Any Ideas?

 

[HT32BSX115]

Re: Trim sender bolt broke

I was adjusting the trim sender on my 1989 5.7 Cobra drive today.
The lower bolt broke off so we drill it out OK and in the process of running the tap in the hole the tap also broke off also.
So now I have a broken tap in the hole and no way to get it out as the tap is too hard to drill.
I have the sender fastened to the drive with the top bolt and it works for now but I don't think it will hold without the lower bolt.
Any Ideas?

Well, you're kinda stuck. If you cannot get the tap out, then 1 screw is what you're going to use. I might put some JB weld on it to help hold it in place.

The trim gage is really not all that critical.......Trim adjustments are usually all by feel.

 

[Idlespeedonly]

Re: Trim sender bolt broke

There is a company by the name of walton. They make an extractor that uses little fingers that slide in the flutes. They work pretty good if it is used properly.

 

[Rocky_Road]

Re: Trim sender bolt broke

There is a company by the name of walton. They make an extractor that uses little fingers that slide in the flutes. They work pretty good if it is used properly.

I have a set of these...and they are not cheap!

We used them to extract taps, but only in clean metal. My guess is that they would fail in weathered aluminum, which can grip like nothing I have ever seen before. If any decent amount of the tap is still exposed, you might have other options.

If you want to try my Walton set...they are for sale! No guarantees, though.

Happy boating!