What caused this part to melt inside the leg? Broken seized bolts

[Wave thumper]

I need some help regarding the merc alpha 1 gen 2 drive I am fitting to my boat. I purchased this as a used good working unit.

Look at this pic, the part behind the main shaft appears to be melted and deformed.
Any ideas an what has happened? Should I drop the lower leg?



I removed the top cap to look at the gears (I thought this would be an easy thing to check!) but 2 bolts snapped in the housing. Any ideas on how to remove them?



I couldn't help posting a pick of the leg jack I made. Thanks to the photos provided by Iboats Mercruiser forum members. It makes installing and removing the leg a breeze!

 

[oldjeep]

Re: What caused this part to melt inside the leg? Broken seized bolts

The way I would normally remove broken bolts would be to stick a nut that is a size too big over the remainder of the bolt and then weld it to the bolt. The heat helps break it loose and then you have something to put a wrench on. I'd steer clear of easy outs, seems like mostly what they are good for is breaking off.

 

[Don S]

Re: What caused this part to melt inside the leg? Broken seized bolts

Look at this pic, the part behind the main shaft appears to be melted and deformed.
Any ideas an what has happened? Should I drop the lower leg?

It's the guide tube for the water tube. It melted do to lack of water. Probably because of a bad impeller. Yes, you should drop the lower, that's how you get to the impeller.

The broken bolts are another problem, heat would have gotten them loose BEFORE you broke them, now, you better find a machine shop.

 

[Bondo]

Re: What caused this part to melt inside the leg? Broken seized bolts

I need some help regarding the merc alpha 1 gen 2 drive I am fitting to my boat. I purchased this as a used good working unit.

Look at this pic, the part behind the main shaft appears to be melted and deformed.
Any ideas an what has happened? Should I drop the lower leg?


I removed the top cap to look at the gears (I thought this would be an easy thing to check!) but 2 bolts snapped in the housing. Any ideas on how to remove them?


I couldn't help posting a pick of the leg jack I made. Thanks to the photos provided by Iboats Mercruiser forum members. It makes installing and removing the leg a breeze!

Ayuh,.... You were Lied too....

That's the water tube, from the impeller pump you see in there....

It's been run Hard, 'n very HOT....

Yer gonna need O2/ Ac touches to get them broken bolts out,...
Heat 'em up, Hot, 'n quench 'em with cold water,...
They may come out the 1st time, or may take repeated quenchin'...
Atleast ya got a nub to work with....

Weldin' a nut on 'em might work, but you'll need a stick welder, 'n alloy rods...
Still quench, before turnin',... don't wanta pull the threads out...

 

[Oshkosh1]

Re: What caused this part to melt inside the leg? Broken seized bolts

Looks like your water tube melted, and I think I see witness marks indicating some blistering on the plastic upper housing...the blackened shaft isn't a good sign either. The tube/seal and upper oil seal should probably be replaced, as well as the impeller which is probably toasted too.

And look to see what remians of your exhaust shutter(s)...

 

[oldjeep]

Re: What caused this part to melt inside the leg? Broken seized bolts

Weldin' a nut on 'em might work, but you'll need a stick welder, 'n alloy rods...
Still quench, before turnin',... don't wanta pull the threads out...

Mig welder works fine with standard wire as long as you've got a decent welder (not some little 110v thing) - but good point about the threads being in aluminum.

 

[Eric 3.7LX Alpha 1]

Re: What caused this part to melt inside the leg? Broken seized bolts

The plastic water guide melts when there is lack of water flow, melted from exhaust, it comes with a new complete impeller kit.

 

[Bondo]

Re: What caused this part to melt inside the leg? Broken seized bolts

Mig welder works fine with standard wire as long as you've got a decent welder (not some little 110v thing) - but good point about the threads being in aluminum.

Ayuh,.... The bolts are SSteel,....

Not sayin' it won't work, but mild steel filler wire don't stick so good to SSteel...

 

[oldjeep]

Re: What caused this part to melt inside the leg? Broken seized bolts

Ayuh,.... The bolts are SSteel,....

Not sayin' it won't work, but mild steel filler wire don't stick so good to SSteel...

Jeeze - I'm batting .000 today. I think I'll go back to working on cars

 

[ktbarrentine]

Re: What caused this part to melt inside the leg? Broken seized bolts

As hot as it got in there (that caused the guide tube to melt), you may also have experienced deformation of the waterpocket cover. best give that a really good look-see when you get the drive split. And if you go after those bolts (on the waterpocket cover), you best hope they dont break! That usually means a new upper is in your future. Just sayin'.... I've seen the guide tube melted like that before with luckily no issue to the water pocket cover, but you dont know until you look close.

 

[Don S]

Re: What caused this part to melt inside the leg? Broken seized bolts

It's a Gen II, no water pocket cover or the worry about those bolts breaking.

 

[ktbarrentine]

Re: What caused this part to melt inside the leg? Broken seized bolts

That's good!