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Oil pressure sender fitting broke off.

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  • Oil pressure sender fitting broke off.

    While attempting to remove my oil pressure sender to replace it, I somehow broke the elbow fitting off. The entire assembly had been painted red and it snapped instead of breaking free from the adapter. I removed the adapter from the engine and tried to remove the broken piece with an easy out but it split the adapter instead of removing the broken piece. I’ve ordered both the adapter and the elbow fitting but they won’t be here for a week or two. If I can match up the thread size, can I just put a plug or bolt in the hole for now and still run the engine? Assuming I would also need to unplug the oil pressure switch to prevent the alarm from going off. I have a fishing tournament I need my boat for and I’m hoping I can come up with a solution. It’s a Volvo Penta 4.3 gl-a. Thanks for any help.

  • #2
    The small fitting should be 1/8 NPT and the bushing that its in, is a 1/4 NPT. Yes you can install plug, and unplug the sender
    94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
    95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
    07 Seadoo GTX
    Merc Adults Only VP Adults Only
    G-Dad always said "First Liar doesn't stand a chance"

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    • #3
      Awesome that’s what I assumed but I wanted some confirmation before I did it. Need to get this boat back on the water. Appreciate the information.

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      • #4
        That adaptor should be fairly easy to obtain locally. Try Autozone or Advanced Auto. I found some there but you need to ask at the desk. They were not on the shelf.

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        • #5
          Originally posted by 3.7L Mercruiser Model 470 fan
          As an after thought, can you use JB weld as fix for now?
          Don't do that
          94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
          95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
          07 Seadoo GTX
          Merc Adults Only VP Adults Only
          G-Dad always said "First Liar doesn't stand a chance"

          Comment


          • #6
            Originally posted by 3.7L Mercruiser Model 470 fan
            I don't know anything about your engine block. Aluminum or Steel block? Can you monitor oil pressure anywhere else in the block? I would not run an engine without monitoring oil pressure some way.

            If any of the adapter remains in the hole, As a general fix, I suggest you drill out, but not all the way leaving enough of the sender to leave a good bite for an easy out that you can get at northern or harbor freight or most hardware stores to remove broken bolts. Be sure not to drill too much and don't allow debris to get into your engine block using vacuum cleaner while drilling. If the hole becomes too big for any reason, you can fix the hole with brasing rod if steel and low temp rod made by blue devil if Aluminum until you can fix the hole for new sender when you have more time. I think products made by this company can help you. The products can be ordered on line at Amazon or others.
            Blue Demon BDTP-125-01T Triple Play Low Temp Aluminum-Zinc Brazing Rod 1/8" x 18" 1 Lb Tube
            Cast iron block, so AL rods will not work.

            Not a JB Weld fixable problem, either.
            BOAT SPECS FORUM HELP STARCRAFT FORUM SHOP iboats
            Please, no PM's (Private Messages) regarding boat/engine problems.
            That is what the forums are for.
            Only forum/moderator issues will be answered in PM's.

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            • #7
              I would try a little bit of a PB Blaster soak and then see if you can easy out the broken off portion. If that won’t work, perhaps a bit of heat will break it free enough with the ez out.

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              • #8
                use an easy-out and back it out.

                or hammer in a torx bit and turn out

                worst case, grease up a left handed drill, or pressurize the oil galley drilling with compressed air when drilling to blow chips out vs letting fall in. then chase with appropriate pipe tap
                Cheesehead boating the Gulf Coast of FLA 27.51° N, 82.53° W

                1988 Cruisers Rogue 2420 -VP 290 DP now powered by custom 468 - https://forums.iboats.com/forum/owner...988-rogue-2420

                Past Boats
                1970 Wooster Hellion - Merc 9.8
                2002 SeaRay 190BR - 5.0 - A1G2 - "Cheeseheads in Paradise"
                1984 Avanti 170DLI -3.0 stringer- "Ship Happens"

                What’s behind you doesn’t matter.Enzo Ferrari

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                • #9
                  The adapter came out of the engine block with no problems. The elbow broke off inside of the adapter. I tried an easy out but it split the adapter in half instead of removing the broken piece. I actually had a brass 1/4” npt plug and it fit in the engine hole nicely. I have tightened it down but have not had time to test run it yet. That should get me by until the new parts come in. Luckily I didn’t break anything off in the actual engine itself.

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                  • #10

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                    • #11
                      Ok. Now I see how it broke. The one I had on the 5.7GSI broke exactly the same way. I was able to find suitable replacement parts at Autozone. The only thing they did not have was the exact duplicate of the part that screws into the block. They had something similar though. It was slightly longer but worked.

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                      • #12
                        go to NAPA or Lowes or Home Depot or Ace Hardware they have those brass parts in stock as well as steel

                        nothing special about the parts

                        the 45 degree elbow is what broke

                        get a new bushing (the male-female part) and a new 45 degree elbow. what you have is a 45 degree street elbow

                        that combination is because there is not enough room to screw the gauge sender directly into the port on the block

                        its angled because of the distributor

                        you can get a 1-1/2" long close nipple and a 45 degree elbow as well.
                        Cheesehead boating the Gulf Coast of FLA 27.51° N, 82.53° W

                        1988 Cruisers Rogue 2420 -VP 290 DP now powered by custom 468 - https://forums.iboats.com/forum/owner...988-rogue-2420

                        Past Boats
                        1970 Wooster Hellion - Merc 9.8
                        2002 SeaRay 190BR - 5.0 - A1G2 - "Cheeseheads in Paradise"
                        1984 Avanti 170DLI -3.0 stringer- "Ship Happens"

                        What’s behind you doesn’t matter.Enzo Ferrari

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                        • #13
                          I checked at Home Depot and didn’t see anything that size. I might swing into Napa and see if they can match it up. I received my new oil sender already. Thanks for the tips.

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                          • #14
                            On the 5.7l it was pretty tough to get a wrench on it because of the distributor. I ended up purposely snapping my sender off so I could get a wrench on the piece that screws info the block. I replace with a tee fitting so I could attach a mechanical oil pressure gauge so I could figure out if I had a dash gauge issue or sender issue. Turned out it was a wiring issue in the end.

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                            • #15
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                              Wiring to the gauge? I keep getting low oil pressure after cruising and then dropping down to neutral. Like clockwork, oil pressure alarm starts going off and gauge shows low oil pressure. Hoping the new oil pressure sender fixes that issue. I tried cleaning up the wiring on the old sender first and it didn’t help.

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