1976 evinrude 9.9

Hi, any idea on how can I remove these bolts; I remove the lower unit to change the impeller and broke about 6 of them. I will really appreciate any help.<br />Thank you<br /><br /> <center><br /><img src=http://img.photobucket.com/albums/v11/sportcraft17/Image607.jpg><br /><br /><br /></center>

Re: 1976 evinrude 9.9

looks like u still have somthing to bite onto. i would heat it with a torch and cool it with pb blaster do that about 4-5 times then hit it again and get on broken bolt with a good pair if vise grips work it back and forth. heating and cooling with penetrating oil will pull the oil into the threads. dont heat the bolts heat the aluminum where the bolts go into.u wanna expand the aluminum not the bolts.

Re: 1976 evinrude 9.9

If Wayne's method does not work you will probable have to drill them out and retap them.

Re: 1976 evinrude 9.9

Like wayne says use vise grip brand not the cheapies. Cheap ones will just get you in more trouble.

Re: 1976 evinrude 9.9

I would take it to a machine shop if you like this motor (I have a 75). They know the "tricks." I doubt that you can get vise grips on at least one of the four in the picture.

Re: 1976 evinrude 9.9

Hi guys thanks for all you replays, I did try with vise grip and one of the screws broke, you can see it on the picture, if I try to drill them out will it work? And How I should do it?<br />I really appreciated all help<br />Thank you

Re: 1976 evinrude 9.9

You have to soak them in penetrating oil first. Use the heat trick suggested above so you don't have to drill out all four. If you must drill them start with a very small bit to get a pilot hole. You must have these holes perfectcly straight. Then use bigger bit for a larger hole. You may then be able to use an easyout but only after soaking and heating as stated above. If you get off center then it has to go the machine shop.

Re: 1976 evinrude 9.9

look on ebay for that part i have seen them sell for 10 buxs might be worth just getting another 1 since that 1 is gonna take some work.

Re: 1976 evinrude 9.9

Hi guys, thanks for all your help. I try all of the above a guess what I broke all the remaining screws, now the only solution is to drill them out, I try to drill them out and no luck, so what I did was to use a drill bit the size of the screws and drill the screws now I have to make a new tread for the new screws, I check the spacer on eBay and one seller have the hole kit for $60.00. I only need the spacer, any idea where I can buy a used spacer in Fort Lauderdale, Florida or any of you guys may have one that you don't need and would like to sell it. Or any Advice on what I should buy to do the treads. <br />Thank you

Re: 1976 evinrude 9.9

Eula30, I'm sorry to hear you had so much trouble but it's what I expected after your first pic. That darn aluminium oxide grabs onto those bolts like nothing else. Coat them in sealer and it won't happen next time.<br /><br />Normally to cut threads you use a tool called a 'Tap', as in a 'Tap and Die' set. If you've had no experience using one, I strongly suggest you try on some scrap aluminium first. The taps are very brittle and if you break one off taping new holes, you'll be in bigger trouble.<br /><br />If I understand you correctly, you've drilled out to the 'inside' size of the bolts' thread and want to tap new threads to accept the same sized bolt as was in there before. Am I correct in that?<br /><br />If not, you have two choices: tap for a larger bolt or install a heli-coil. The heli-coil is the better route as it allows you to put things back to 'stock' with superior threads then the original. And you won't run into bolt-head size problems. Plus, the heli-coil kit comes with it's own tap, so you won't have to purchase a set, just a tap wrench.

Re: 1976 evinrude 9.9

Hi there, yes I have drill out to the inside “ size” of the bolts and I can make new threads to accept the same sized bolt as was in there before. This is the first time I hear about helix-coil, I check on the web and to me I think it is going to be easier for me to use the Helix-coil, than buying just the tap and die set. I don’t have any experience with making new threads but hey I will give it a shot and see how it goes. Now where I can buy the Helix-coil, any auto parts like: AutoZone, Napa, etc….<br />I really appreciated all of you for hang in there with me, I now my English is quite ruff but hey I’m learning day by day and I’m getting there.<br />Thank you