3.0l mercruiser 99 bayliner starter bolt broke off

[Masarudizz]

No Title

 

[funk6294]

Can't tell if that is a crack or a flashing mark from the casting process. Can it be seen on the outside of the bellhousing? As for the drilling it looks like you had one that was pretty on center. How far in do you think you got the drill bit to go? If you have enough depth you could use an easy out to see if it will loosen. Also since that is on the out side starter bolt, is the bolt hole open on the top? If so you might be able to work backwards from that side. If you need to punch a center mark, with the bolt recessed in the hole it might be easier to use a transfer punch that will fit into the hole. This way it will stay centered. If you don't have them they can be had cheap at harbor freight.

 

[Masarudizz]

The top can't b seen

 

[Masarudizz]

Holy crap I did it thank u so much everyone ! I am appreciate everyone's help/advice in this very gruesome time consuming process but I did it n saved myself 600$ thank u so much everyone

 

[81 Checkmate]

You are very welcome...... Run a tap in the holes....very carefully not to break it off, use oil with it........Get new bolts and make sure the end bracket is installed on the starter.

 

[funk6294]

Alright, way to go!!!!

 

[Masarudizz]

Run a tap? I already screwed in the new bolt I didn't run a tap? But it seems to b sturdy and Iam installing the bracket today as well

 

[Masarudizz]

The bolts are really tight on there do I need to torque it or it should b fine ?

 

[Bondo]

The bolts are really tight on there do I need to torque it or it should b fine ?

Ayuh,.... I use a calibrated elbow, but yer lookin' for 35/ 40 ft.lbs.... standard for 3/8"-16 bolts,....

 

[Anton_Kor]

I did this repair with the engine in the boat. The process seems more stressful when reading, than the real work involved. Might be luck.

Tools: a mirror, flashlight, insulating tape, 90 degrees right angle battery powered drill with a left-hand spiral extractor (http://www.irwin.com/tools/screw-bolt-extractors/10-pc-spiral-extractor-drill-bit-combo-pack), friend and beer as a gift.

First thing is to center punch a hole in the base (broken end) of the bolt body. I used a `’max`’ size bit, from the above linked set, wrapped with electrical/insulating tape to the size of the hole. 3-5 minutes needed to tap the center.

Then, drill with “middle” size bit. One person holds the drill aligning to the bold axis and the second person, reaching from above the engine pulls the drill to apply the needed pressure against the bolt. 2-3 minutes and you get an inch, it’s enough for using a spiral extractor.

Pretty much, that’s it. Be careful and good luck.