3.0l mercruiser 99 bayliner starter bolt broke off

[Masarudizz]

So I am new to this website ,me and my fiancé jus bought a 99 bayliner with a 3.0l mercruiser we took it out for the first time ran great but then I heard something n looked n found that a long starter bolt was laying on the ground not the shorter one the shorter one is still in there I'm assuming because after this happened I took it out to the lake again and it runs fine but at 10 mph I can hear a ticking or a little rattle at low speed then I speed up n it goes away n it jus started doing that once that bolt broke off it is still inside there where its threaded so they said the only way to get the remainder bolt out n put a new one is to drill it out n in order to drill it out they need to pull the engine well I don't have that much money so I will not b doing that so I am open for any ideas or pictures of how to do it or videos or what it looks like underneath there bcuz I can't see without pulling the engine even a picture of where the bolts are inserted underneath would b nice even if its a starter not mounted would be nice thanks ! And is putting something there to wedge the bolt there a bad idea or would it b ok If I can't figure out how to get the broke part out can I jus take the broke starter bolt n try to jbweld it in n will that work I kno it's not a good idea but I'm seriously considering it thanks for any help pics or vids or step by step instructions it's greatly appreciated thanks

 

[Masarudizz]

Help please

 

[bilge rat jim]

A starter needs 2 bolts to hold it in, that's why there is 2. A wedge is not a bolt. And what "they" tell you is true- the engine needs to come out to remove the broken bolt. Removing the engine is relatively easy, if you have a manual, some basic hand tools, and a way to remove the engine. The engine removal section of the manual can found online, the tools can be had from wally-world, and a tree with a stout limb and a come-along is only a slightly dangerous method of removal.

 

[Bt Doctur]

You need both bolts and the starter bracket, no if`s and`s or but`s, engine removal is the best method to make the repair

 

[Masarudizz]

Would it ruin anything if I jus tryed to use a jb weld n that would basically glue it onto the remainder sticking out I kno it won't b a permanent fix but could I do that with out ruining anything ? Can anyone post a pic of what it looks like down there or how it mounts up n where the bolts go so I can see what I'm kind of doin while trying to do this blind with a mirror ! Because I won't have the money to pull the engine for a long time if ever so that's kind of out of the question

 

[Masarudizz]

Can someone shoe me pics of what it looks like down there n where the bolts go ? I don't have the money to remove engine I'm gona try n do it blind dang near with a mirror or I will jus try n take the bolt n jb weld it onto the remainder bolt sticking out will that ruin anything if I do that jb weld idea it can't hurt anything ?

 

[jackd1023]

you can try to mig weld a nut onto broken bolt seeing as cast is so hard to weld to, otherwise pulling engine is only option. I would be concerned on why it broke, hydrolock? wrong bolt(metric/standard)? maybe thats why they sold it?

 

[Masarudizz]

It looked like it was air wrenched on? What is hydro lock? So if I jus put a Lil jb weld on the end of the bolt n stuck it up to the broke en off piece n it formed solid the next day n stayed n didn't break off would it b ok to drive it does all that bolt do is hold the starter in place so it don't wiggle and stays aligned with flywheel maybe I could also wedge something under the starter to keep it from moving n keep it kind of secure

 

[Masarudizz]

Would it ruin anything if I jus tryed to use a jb weld n that would basically glue it onto the remainder sticking out I kno it won't b a permanent fix but could I do that with out ruining anything ? Can anyone post a pic of what it looks like down there or how it mounts up n where the bolts go so I can see what I'm kind of doin while trying to do this blind with a mirror ! Because I won't have the money to pull the engine for a long time if ever so that's kind of out of the question

 

[jackd1023]

There is a whole lot of torque in a starter motor, what will happen is round off or break off teeth on the flywheel, then for sure you are in pulling engine stage, can also crack the block then its engine replacement, JB weld will adhere to the engine block too and make it impossible to get that broken bolt out. I would borrow or have someone you know tack weld on a nut to the bolt and try to wrench it off. Hydrolock is a term that means there is Liquid, (water, fuel,antfreeze) in one or more of the cylinders that cannot be compressed causing the motor to lock up ..putting huge amounts of stress on starter and flywheel

 

[fishrdan]

JB weld isn't going to work, you need to remove the broken bolt and replace it with a good one.

Engine removal is going to be the best method of repair, but if you are good, (REALLY GOOD) you may be able to work the broken bolt out of the hole with the engine in place. Left handed drill bits, pick, working backwards with a mirror, contorted upside down in a bilge........

Click a few pictures with your smart phone so you know what it looks like up under there.

 

[Masarudizz]

Thank u so much I appreciate all the advice! And anyone else want to add in anything or has anything extra to add I will be very great full before I try to attempt the impossible

 

[Masarudizz]

I also have took it out on the water last weekend no noise unless I'm going slow when I go fast I don't hear nothin should I be worried about my flywheel ?or the teeth ?

 

[fishrdan]

With only the outside bolt holding the starter, I'd be most worried about snapping the ear off the block's skirt... Snap the ear of the skirt off,,, and the block will need to be replaced, instead of just a bolt.... :faint2:

 

[funk6294]

How sure are you that the bolt broke off flush with the block? Depending on where it broke if there is enough left sticking out you may be able to remove the broken piece with a set of vice grips. Also if your not comfortable it maybe worth consulting a mobile mechanic to see if they have some other ideas. Removal of the engine maybe what was easy for the first shop. You need to find someone that is willing to put that extra effort in.

 

[Masarudizz]

I'm not sure yet ill get down there tmrw n take some pics to see what ill b workin with , and when messing with the starter I assume I should disconnect the battery , which cable is it again that I should disconnect first positive side then negative side ?or it doesn't matter?

 

[81 Checkmate]

Take the positive off first at the battery.......Like someone else said the bolt may have broke off long...ie above the flat surface of the starter..... then if it's stuck outa the block get a pair of vise grips and remove the bolt....... Remove the starter and have a look....could get lucky!


Better do something now or........ if you continue to run it you will only create more problems and more money!

 

[Fishermark]

Take the positive off first at the battery.......

Actually it is better to take the negative off first, then you don't need to worry about the wrench hitting something when you take the positive off.

But yes - I agree that you need to drop the starter and see what you have left. The good news is the piece remaining is usually not in the block very tight.

 

[UNSUREBOATGUY]

I did this repair with the engine in the boat. I had pretty good clearance, but it was still a real pain and took a lot of patience working upside down with a mirror, etc. It might take a couple of days so you don't get fed up and set the boat on fire Maybe you'll get lucky and it will come right out. Here are my suggestions based on my experience:

1. Be sure to use a center punch to start a dimple in the bolt before you start drilling so you don't slip off and damage the block.
2. Reverse bits are the way to go-start small with cutting oil/penetrating oil, and move up to larger sizes after you get a decent depth hole. If you are lucky, it might come right out when you switch to a larger size.
3. Don't use an easy-out. Angles are bad and it's too easy to break it off in the hole making your problem much worse.

If these things don't work, you'll just have to pull the engine and work on it with more clearance and at a better angle. The goal is to not damage anything else that might cost you a block or starter.

Once you get the broken bolt out, install new starter bolts designed for your engine and starter, so the new ones don't break too. On that note, if there is not a bracket at the front of the starter holding it to the block, buy one or make one-it really helps take stress off the two main bolts.

Good luck.

 

[UNSUREBOATGUY]

This is assuming the bolt broke off in the block. If you drop the starter and see the bolt sticking out of the block, you might be able to remove it with vise grips as mentioned.