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  • Oh no! Now what? Starter bolt hole cracked.

    1993 Merc 4.3LX.
    Pulled the starter, pulled the motor and replaced the ring gear.
    While putting things back together I found the hole that supports the starter is cracked. Probably why I had to replace the ring gear.

    How can I fix this?
    Attached Files
    2008 82' Sunseeker Predator...... Gotta hit the Lotto.

  • #2
    Re: Oh no! Now what? Starter bolt hole cracked.

    Originally posted by Hogger View Post
    1993 Merc 4.3LX.
    Pulled the starter, pulled the motor and replaced the ring gear.
    While putting things back together I found the hole that supports the starter is cracked. Probably why I had to replace the ring gear.

    How can I fix this?
    I agree that is what messed up your ring gear. Only fix is a new block or a competent welder and a good machinist. Either way that motor has gotta come out. Sorry...
    sigpic

    1969 StarCraft Chieftain, 4.3 Mercruiser Alpha One Gen II

    Link To Restoration Page


    ----------------------------------------------------

    Its What I Don't Say You Should Be Worried About...

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    • #3
      Re: Oh no! Now what? Starter bolt hole cracked.

      weldiing it will only create problems

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      • #4
        Re: Oh no! Now what? Starter bolt hole cracked.

        Just thinking out loud. Did some digging around and it seams some hot rod guys with busted blocks use this trick. I have no idea if it will work, but what the heck...

        Problem would be finding a marine grade starter for a SBC 265. Or maybe you can put the nose cone from a 265 starter on a marine starter motor...

        http://www.danchuk.com/ItemForm.aspx...5-ceabc840a895
        sigpic

        1969 StarCraft Chieftain, 4.3 Mercruiser Alpha One Gen II

        Link To Restoration Page


        ----------------------------------------------------

        Its What I Don't Say You Should Be Worried About...

        Comment


        • #5
          Re: Oh no! Now what? Starter bolt hole cracked.

          Originally posted by boat127 View Post
          weldiing it will only create problems
          As if the cracked block isn't creating any???
          sigpic

          1969 StarCraft Chieftain, 4.3 Mercruiser Alpha One Gen II

          Link To Restoration Page


          ----------------------------------------------------

          Its What I Don't Say You Should Be Worried About...

          Comment


          • #6
            Re: Oh no! Now what? Starter bolt hole cracked.

            Originally posted by boat127 View Post
            weldiing it will only create problems
            Welding is fine if done by someone competent in welding cast iron.
            I've had head bolt holes welded and they were fine.
            You might see if a staggered bolt pattern starter would fit and drill a new hole.

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            • #7
              Re: Oh no! Now what? Starter bolt hole cracked.

              That is one of the worst I have seen, but since basicly you have nothing to loose, you could peal that chunk out. Take a die grinder and rough it up pretty good, fill it with JB Weld and thn redrill and retap the hole. I have gotten away with this when PART of it was broken, but I will say this is worse than one I had to fix.


              This block held about two years......
              Jezzebelle-1999 Pursuit 2870 w/ Twin Yamaha 225's
              Guppie-1996 Allison Sea Max 17 w/ Mariner 75

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              • #8
                Re: Oh no! Now what? Starter bolt hole cracked.

                I hadn't looked at your picture before I suggested you look for a staggered starter. Outside hole so it won't help.
                I saw one block several years ago, where someone took a starter bolt and cut the head off of it and welded it in upside down. Then they just put a nut on the threaded portion after the starter was in place.

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                • #9
                  Re: Oh no! Now what? Starter bolt hole cracked.

                  that counter bore in the block for the starter holes, look close its there.
                  its sole function in life is to grab the knurled portion of the NEW starter bolt and hold the fastener tightly preventing any lateral walking.
                  the new PGM starters made the issue worse and the quickest way to shear bolts and break blocks is reusing a starter bolt on a PGM starter or under torqueing the bolt.
                  you can try having it welded, you will be out the cost of whatever the welder charged at worst.
                  if it doesnt work your back to replacing a block.
                  never seen a weld hold long there but you can try it.
                  problem with welding cast iron is about the same as machining it. its kinda like a hard sandstone.
                  no tech questions by PM, they wont get answered.
                  you have to be trusted by the people that you lie to .

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                  • #10
                    Re: Oh no! Now what? Starter bolt hole cracked.

                    Only thing I can think of to do with out pulling the motor is to glue a stud in with J-B weld and use a nut. Looks like you still have over half of the diameter of the hole.
                    sigpic
                    23' Nordic Viking
                    500HP BB Chevy
                    TRS Drive

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                    • #11
                      Re: Oh no! Now what? Starter bolt hole cracked.

                      Originally posted by picklenjim View Post
                      Only thing I can think of to do with out pulling the motor is to glue a stud in with J-B weld and use a nut. Looks like you still have over half of the diameter of the hole.
                      I have done this before on sb chevy's. It will work and will be strong. No need to pull the motor, just take your time and don't use quick set jb. Get the long set it will hold better. Comes for people either over-torquing or cross threading the bolt. Starter bolts do not go on with breaker bars or impact guns. Not saying you did it.
                      1971 gregor 9.9 14 foot
                      2009 tracker 1754cc 40hp merc

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                      • #12
                        Re: Oh no! Now what? Starter bolt hole cracked.

                        Before you go to the time to jerk the motor out, I would definately try JB weld, drill the hole back out, and tap it. To be honest, even with a competent welder, cast is very difficult to get to hold.
                        Super Bad Awsome
                        1992 Rinker 206 Captiva, 4.3 Merc. LX 4BBL
                        "Don't take life so seriously, you may never get out of it Alive"

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                        • #13
                          Re: Oh no! Now what? Starter bolt hole cracked.

                          I'm on board with the JB welding a stud in there and then using a nut on the other side of the starter.. If that didn't work my attempt would be to mig weld a stud to the block.
                          2017 Lowe SS210 Tritoon with Wavetamer XL package, 2017 Mercury 115 Pro XS with command thrust, and 2017 Karavan trailer.

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                          • #14
                            Re: Oh no! Now what? Starter bolt hole cracked.

                            and end the end, you will most likly replace the block.
                            if you attepmt the JB weld or weld method go find the big case old stye delco starter.
                            if you use the late style PGM it will crack again fairly quick.
                            no tech questions by PM, they wont get answered.
                            you have to be trusted by the people that you lie to .

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                            • #15
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                              Re: Oh no! Now what? Starter bolt hole cracked.

                              Once you get the bolt JB'd in take and drill the proper size to put a roll pin through both the block and the bolt for extra holding power.

                              A staggered starter won't work as the staggered bolt is inside one. The broken hole shown is the hole common the both starters.
                              When will people learn that impellers require regular
                              replacement and are not drive it till it pukes items?

                              1984 Regal Medallion 195
                              3.8 V-6 with the dreaded
                              OMC Stringer Drive.
                              2003 Avalanche w/Hypertech

                              If it ain't fixable - don't break it!

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