Alpha Gen 2 Bellhousing Continuity Wire - Replace?

[JoLin]

The screw holding the wire to the bellhousing on my port drive is frozen. Can't loosen it (tried heat gun and PBlaster) and I'm starting to bugger up the screw head. On the starboard drive, the wire is broken. Haven't tried to remove the screw(s) there yet, but don't expect much better luck. I assume I'll need to drill the heads off the screws to get them off, or cut the wires.

I know I need to buy 2 continuity kits, but it's doubtful that I can use the same mounting screws and holes. Anyone drilled and tapped new mounting holes for this? Tough job? I've never actually used a tap, so looking for a little guidance/moral support.

 

[Bt Doctur]

Have done the replacement many times, you can grind the screw head and save the wire end. to install, you use the correct size drill bit for the thread your using.
most taps come with the correct drill 8 x 32 or 10 x 32 thread

 

[Scott Danforth]

I use a steel drift and a big hammer. smack that screw on its head, apply penetrating oil, wait a few minutes and smack again. this helps loosen the corrosion holding it to the aluminum. (stainless and aluminum really do not play nice together from a galvanic point of view)

most of the time, this is all that is needed to get the stuck screw out. if it doesnt work and the screw strips out or breaks, then drill and tap time.

Since you have never used a tap, especially in aluminum, I suggest you practice. I often start my tap dry, then use tapping oil. however my old machinist neighbor said to use crest tooth paste when taping aluminum. he also used it to lap valves

 

[Bt Doctur]

Don`t you just hate it when us oldtimers start giving up our secrets

 

[JoLin]

Appreciate the input, guys. I know it isn't rocket science and I can figure it out, but no matter what the issue, somebody on this forum has dealt with it. The outdrives are the originals (1992). They're in good shape for their age, but I do run into the occasional issue caused by many summers in salt water. Also doing outdrive maintenance for the first time, so I've been searching all the good threads here.

Even I thought it was funny that in 50 or so years of DIY, I've never had occasion to tap threads in anything. Strange.

Thanks again!

 

[Bondo]

Ayuh,.... Have ya got a hand-impact driver,..??

With the right bit, Try it,....

If ya ruin the screw, the housin's are aluminum which drills, 'n taps easily,....

I've seen some of the screws that self-tap into pre-drilled holes,.... aluminum bein' so soft,...
They were more of a machine thread, rather than the usual real coarse thread sheet-metal screws,....
No part number though,....

 

[JoLin]

The wire is off. I don't have an impact driver so wound up drilling the screw head, then knocking it off with a screwdriver and hammer. So, I got the bellhousing off. When I looked at the other end of the wire, inside the swivel housing, my reaction was 'rut-roh'. How the heck will I get a drill in there'?? Hope springs eternal, so I got my stubby philips screwdriver, put my channel-locks on the handle, gave it a turn, and the screw came right out. Go figure. I hope the same will happen when I work on the other drive.

Next step is to buy the tap and some new screws. I'm going to see if there's a hex-head machine screw I can use instead of the philips. I'll also look to see if I can find any self-tapping screws that Bondo mentioned.

 

[poconojoe]

The screw on my Alpha 1 Gen2 is Allen. I used an Allen socket and the head broke right off. Got an exact stainless replacement screw at my local Ace hardware. I think it was a 10-24 thread. Drilled and tapped a new hole in the aluminum.