Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

[leviwynnyk]

I bought a new to me boat (1996 Glascon 180 Bowrider witha merc 4.3 LX) a week ago and today I got stranded on the lake, the starter wouldn't work. Upon getting it home and pulling out the starter, i noticed one bolt was at the bottom under the engine. After looking closer, I noticed that the bolt had sheered off inside the hole about 1/4 inch. Also there was some metal shaving from when the gear on the starter was grinding due to being loose i assume. Now how bad of a gear would it have to be te need to be replaced on the starter? Also, I pretty much have to pull the engine right? How hard is this to do or does anyone have good instructions for this? I figure instead of paying someone else to do it and being charged an arm and a leg, I could just buy an engine hoist and I'd have it for other jobs. Also, should the Fly Wheel (I think thats what the big gear is called) have any rust on it like this one? Could this be an even bigger problem? Here are some pics of the starter and the rest. Also, how much "should" I pay to have this done if I were to take it to a Marina? Thanks everyone. Iboats rules!<br /><br />

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[searay3]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

If you didn't clean up the starter, it looks fairly new. The gear on the starter looks ok but can't see the other side. Rotate the gear and if it all looks the same it should be fine. Rotate the motor by hand and inspect the flywheel ring gear for broken teeth. If none, it should be good as well. I think you may have bigger problems. Was there only one bolt and maybe the front bracket holding the starter in the first place. The pic with the flywheel/ringear has a broken casting. Is that where the front bolt would be? ? When the bolt broke, did it seem like the engine stopped abrubtly (hydroloc)? Could be that the starter wasn't mounted correctly, or there may be bigger issues.

 

[KaGee]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

Rust on the flywheel is normal. It's hard to tell if the flywheel is shot. I would definetly replace or refurbish the starter.<br /><br />The broken bolt is another story. As far up as it is it will be difficult to remove with the engine in the boat.<br /><br />Somebody else may have toughts about the flywheel.

 

[elpaso]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

Go to search, and type this -<br /><br /> mercruiser starter mounting bolt broken

 

[Bt Doctur]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

From what I can see it looks like you only had 1 bolt in there.The broken one can be removed but the block casting will need to be repaired.Id drill it out to say 1/2 or 5/8 ths. retap and install a threaded insert,try to weld up the missing area of the block with/to the insert,install starter ,locate new hole using starter as a guide,drill and retap to original.Make sure the new bolts are the correct lenght or else it will happen all over again.

 

[Fishermark]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

There is a recent post about removing a starter bolt from a block with many good suggestions. Yes, you will have to remove the engine.<br /><br />Looking at your pictures reminds me - I once had a pickup truck with a small block chevy and it had the corner broken off the block like yours. The starter would flex wherever I tried starting the engine and would eventually start "grinding." The solution was to add the front bracket that holds the front of the starter up to the engine block. It apparently was an option for some starters, but if I'm not mistaken, all the blocks have the provision for this bracket to be added. Yours may already have it, if so, great! If not, I strongly suggest you add it. Then the broken corner will not come into play.

 

[Bondo]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

From the pictures I can see that you've got Problems..............<br /><br />1) The starter bendix can be cleaned up with a small File or Emery Cloth,..... No Problem......<br /><br />2) The Ring-Gear can be driven off the flywheel,+ Flipped over,+ Reinstalled,....... No Problem........<br /><br />3) After the engine has been pulled,.. The Broken Bolt can be drilled,+ Easy-Outed, Out,.......No Problem............<br /><br />4) the outside bolt Hole is Broken,+ the remaining part of it Looks Cracked,..........<br />That's a Big Problem...........<br /><br />I agree with some of the above statements,.. That the Front Mount should be reused, or Added if it's not already there....<br />But I Disagree that it'll take All of the load of the Broken Casting Bolt Hole........<br /><br />Drilling,+ Pinning,... or Welding,... or Creative Engineering is going to be needed to Fix That.............<br /><br />Good Luck.....

 

[leviwynnyk]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

I read through the other posting but wanted to post the pictures. The brace that goes on the engine wastotaly loose and the only bolt that was holding the bolt in is the one that goes into the broken hole. It was actually holding it quite tight and by the looks of things had been holding it like that for quite a long time. I also couldn't find any more cracks on the outside bolt hole other then the piece that broke off. Now I found the small piece of the engine block that broke off and it was rusted making me think it had been missing for quite a while too. My plans were to pull the engine, remove the old bolt and replace both of the bolts with new ones, along with a new bracket. Do you guys think I need to weld that broken piece back on? There were no threads in it at all, but I could take it in to be welded...... <br /><br />I need to know how hard it is to pull the engine? I have never done one but I need to save the $$$ since I haven't even made a payment on the boat yet. Also, where can I get the best manual for this engine. I looked on the net a lot and all the manuals are the Cymer's or the Seloc ones and I read on here that the best is the factory one but couldn't find a good source.<br /><br />Thanks.

 

[Fishermark]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

My plans were to pull the engine, remove the old bolt and replace both of the bolts with new ones, along with a new bracket.

Good plan! <br /><br />

Do you guys think I need to weld that broken piece back on?

Nope. Especially since there are no other cracks around it. Tighten the front bracket up, and it should be fine after the other broken bolt is removed and new bolts installed. (Be sure to get starter bolts with the knurled shaft).<br /><br />

I need to know how hard it is to pull the engine?

That's a relative question of course, but it is actually rather simple - if you have the tools. Buy the engine hoist you mentioned - it will pay for itself many times over. In fact, once you get the hang of pulling the engine you will find yourself pulling it to do "simple" things that could probably be done with the engine in place, but it is easier to pull the engine out of the way. <br /><br />If you do a search for manuals here you will find links to Mercruiser manuals. Here is another site you will probably find handy: "How do I?"

 

[DHPMARINE]

Re: Broken Starter Bolt on my 1996 merc 4.3LX. Advice?

replace the starter with a new (or rebuilt) marine starter.It's not worth playing with.Hopefully your flywheel ring gear will function ok.<br /><br />Find Arco or Arco Marine starters (on lime).I think they explain how important this starter mounting pad is.Maybe ask if they have any solutions.<br /><br />Bad starter mounts don't go away,they just rear their ugly heads on the 4 th of July.When you need the boat.<br /><br />You may go for years with no problem,or only replace the starter every once in a while.But if you have trouble with it frequently,the damage gets worse quickly.And the price soars accordingly.<br /><br />DHP