How to Remove the Power Steering Cooler - 4.3 LX

[JoLin]

I'm replacing manifolds, risers and all the cooling system hoses. I have the port side mani's and risers off, and I'm trying to remove the PS oil cooler so I can get a good look at it. I think it's original (23 years old) and I don't want to put everything back together if this thing is near rusting through (salt water boat).

The cooler sits low down on the port side of the motor. The mounting bracket bolt screws into the block, and the bolt head is between the block and the motor mount. I can see and feel it, but I can't figure out a way to get at it. I'm not equipped to lift the motor and remove the motor mount to gain access.

Appears that if I remove the alternator and bracket, I might be able to get at it from the side, but not sure. Just wondering if anyone here knows something I'm missing.

Thanks.

 

[Bayou Dave]

I just checked my power steering cooler on a 4.3. Removing the alternator makes it a lot easier to get to the hose clamps and the cooler bracket. They should have designed a better way to access that bolt. Good luck...

 

[alldodge]

I'm replacing manifolds, risers and all the cooling system hoses. I have the port side mani's and risers off, and I'm trying to remove the PS oil cooler so I can get a good look at it. I think it's original (23 years old) and I don't want to put everything back together if this thing is near rusting through (salt water boat).

The cooler sits low down on the port side of the motor. The mounting bracket bolt screws into the block, and the bolt head is between the block and the motor mount. I can see and feel it, but I can't figure out a way to get at it. I'm not equipped to lift the motor and remove the motor mount to gain access.

Appears that if I remove the alternator and bracket, I might be able to get at it from the side, but not sure. Just wondering if anyone here knows something I'm missing.

Thanks.

Most are a bear to get at, my 502 was in the same spot. Removing the ALT should help but like most boat stuff you need a little skinny kid to do it

 

[JoLin]

Okay, I bit the bullet while you guys were responding (thanks) and actually did gain access to the bolt head by removing the alternator and swinging it out of the way. I had to get in there with a battery terminal brush (I have one with a longish handle) and clean the crud away before I could get a box wrench on it. My 9/16" wrench had enough play that I was afraid of rounding the edges and finally got a tight fit with a 14mm box wrench.

Of course, the bolt is frozen solid so I'm now starting the long process of trying to free it up. I don't have a torch so I'm using a heat gun, squirts of penetrating oil and a hammer to try and break it free. What a PITA. I'll report back when I either get it out of there or break the head off the bolt...

 

[JoLin]

I've put this project on the shelf for today. I thought the bolt was starting to move, but instead I was just starting to round off the shoulders of the bolt head. That bolt is one of three holding the motor mount to the block, so enough of that idea.

I could hacksaw through the existing bracket and then fabricate an alternate mouting point for a new bracket (doable, I think), or I could just leave it alone and hope for the best. Right now I'm tired and a little frustrated, so I think I'll sleep it.

 

[Bondo]

Ayuh,.... On mine, the bracket wraps around the cooler,...

Take the Other end apart,.... not the end on the motor mount bolt,...

 

[JoLin]

Thanks, Bondo. The bracket does wrap around the cooler, but on mine both ends are under the same bolt. Looks like there might be a small through bolt/screw that tightens it around the cooler. I'll take another look. The bracket itself is so rusty that it's hard to see what's what. If I can remove that, I may be able to spread the bracket enough to slide the cooler out of it. Putting it back together might be an issue, though once I've bent up the bracket.

I'm also considering cutting the old rusty bracket out of there and fabricating something that will bolt to the motor mount at the stringer instead of at the block. There's nothing complicated about the assembly- the cooler just needs to sit in the same spot it was originally, so that the cooling and PS hoses will fit.

I'll take a fresh look at it tomorrow.

 

[Bondo]

Thanks, Bondo. The bracket does wrap around the cooler, but on mine both ends are under the same bolt. Looks like there might be a small through bolt/screw that tightens it around the cooler. I'll take another look. The bracket itself is so rusty that it's hard to see what's what. If I can remove that, I may be able to spread the bracket enough to slide the cooler out of it. Putting it back together might be an issue, though once I've bent up the bracket.

I'm also considering cutting the old rusty bracket out of there and fabricating something that will bolt to the motor mount at the stringer instead of at the block. There's nothing complicated about the assembly- the cooler just needs to sit in the same spot it was originally, so that the cooling and PS hoses will fit.

I'll take a fresh look at it tomorrow.

Ayuh,.... Then it probably wouldn't take much wigglin' it back, 'n forth to snap it off,.....

Leave the tabs under the rusted bolt,...

 

[JoLin]

You were right. About a dozen back and forth wiggles, and it snapped off clean at the bolt head. Of course, in the 'why me?' category:

1. After all that, the cooler looks damned near perfect. No cracks or corrosion anywhere, inside or out.

2. The motor mount is bolted to the block by 3 bolts- two at the top and one at the bottom- a triangle. The bottom bolt (the one I couldn't budge) was the one holding the cooler bracket. Out of curiosity I put a wrench on the top 2 bolts and they both broke free with almost no effort. Note to Mercruiser... if you strap the damned thing to one of the top bolts, folks could at least get to it. Even if they'd been frozen, they're out in the open and there's a lot more room to get some tools in there! Better yet, make a bracket that bolts under the the mount at the stringer instead of the block. Those you can always get out.

Soooo.... I have to dig around and find a couple inch long piece of aluminum bar, drill and bolt one end of it to an upper motor mount bolt, and drill the other end for the new cooler bracket so it hangs down in the same spot it was.

Well, I saved the cost of a new cooler, but I would almost have like to find out it was crap to justify all this ridiculous effort :facepalm: