I twisted off a bolt that holds the water jacket on the head

[tbrownarcher]

I have a 1985 XR-2 Mercury enging 150 hp . I was torquing all the engine bolts and when I got to the water jacket on the left side of the engine one of the bolts was over torqued so i was backing it off and twisted it off. I have tried to use an easy out but it does not budge. we have drilled all the way through the bolt and it does not come out . What else is there to try?
Or someone direct me to a head for that engine ?

Thanks,
Nate

 

[bilge rat jim]

Drill the remainder of the bolt completely out ( you may want to use a drill press for better control) and use a thread repair insert. Heli-coil is the most common name, but i have found EZ-LOK to be a better product.

 

[java230]

Penetrating oil, for multiple days, and heat. If you get the bolt good and hot sometimes it will break the bond.

Good luck! I broke all of them on mine....

 

[Mi duckdown]

this is where left hand drill bits come in handy.

 

[tbrownarcher]

i took it to a guy who drilled it out .... tapped it and the bolt is off center a bit but hardly noticeable ..... we will see what happens i'm putting it on the motor right now
thanks,
Nate

 

[scumfrogmillionaire]

What were the results? Did it leak? I have a very similar problem where the thermostat housing bolts are stuck in the engine block. They will not extract so I'm thinking of just drilling them out and retapping.

 

[Chris1956]

Don't break the bolt. Use heat, penetrating oil, a torque wrench and prayer if needed to coax it out. Breaking it off is the last resort, as the repair may not work due to tolerances.

 

[Tassie 1]

Nearly 4 yr old post,