I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David

dh@. wrote:
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David

They are usually held with locktite and torqued to 90 or 100 ft lbs. You
should use a special 12 point tool instead of an allen wrench.

On Aug 5, 11:55*am, dh@. wrote:
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David

You can also put in at marineengine.com

They have a lot of gear heads there, and a section strictly for
Mercruiser. You can get a free membership. I've met a few fellows that
have been very helpfull there.
Jim sounds right about the locktite..AND the tool. DONT strip that
socket out.
Can you use an impact screwdriver to start it? Wouldn't that " break
" the grip of the Locktite?

dh@. wrote:
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David

Add a little heat (torch) if you can.

D wrote:
dh@. wrote:
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David


A penetrating oil like Kroil or PB Blaster - spray and let sit for a day ot two.

Use the correct tool - 12 point star, if that's what they are. You'll need it.

And don't OVER use an impact driver. Banging (too hard) on the screws with an
impact driver is guaranteed to damage threads in aluminum castings.

Richard

Be very careful dissassembling outboards and outdrives. Many are trashed in
the process of taking them apart. If locktite has been used, the bolt must
be warmed to about 200C to melt the locktite, but the bigger problem is
corrosion. Heat, Kroil, Kerosine,etc all helps. Impact screw drivers (in
both directions) also helps. When built, no anti-seize would have been used
to assemble these and you are now paying the price. You will be very lucky
not to break a screw or bolt.
Steve

dh@. wrote in message ...
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David

On Thu, 6 Aug 2009 06:31:29 +0200, "Steve Lusardi"
wrote:

Be very careful dissassembling outboards and outdrives. Many are trashed in
the process of taking them apart. If locktite has been used, the bolt must
be warmed to about 200C to melt the locktite, but the bigger problem is
corrosion. Heat, Kroil, Kerosine,etc all helps. Impact screw drivers (in
both directions) also helps. When built, no anti-seize would have been used
to assemble these and you are now paying the price. You will be very lucky
not to break a screw or bolt.
Steve

dh@. wrote in message ...
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David


From the exploded view in the link, it appears the holes have
heli-coils in them, which if true, may help a bit.

On Aug 6, 6:10*am, wrote:
On Thu, 6 Aug 2009 06:31:29 +0200, "Steve Lusardi"





wrote:
Be very careful dissassembling outboards and outdrives. Many are trashed in
the process of taking them apart. If locktite has been used, the bolt must
be warmed to about 200C to melt the locktite, but the bigger problem is
corrosion. Heat, Kroil, Kerosine,etc all helps. Impact screw drivers (in
both directions) also helps. When built, no anti-seize would have been used
to assemble these and you are now paying the price. You will be very lucky
not to break a screw or bolt.
Steve

dh@. wrote in messagenews:faaj75h9o95v2avac3sr7cmod4616ronk1@4ax .com....
I'm trying to take apart a Mercruiser outdrive to replace the boots
which have cracked. It looks a good bit like this one:

http://www.boats.net/_search/images/...4198540716.png

I had to go buy a 1/2 inch allen wrench to remove part #26. They're
very tight, possibly rusted, and I haven't broken them free yet. Is
there anything else holding them, or should I get a cheater bar and
apply a lot more force to break them loose? Any suggestions about this
job would be much appreciated.

Thanks!
David

From the exploded view in the link, it appears the holes have
heli-coils in them, which if true, may help a bit.- Hide quoted text -

- Show quoted text -

Don't know about the helicoils.

Do know those are really tight.

I did not tighten mine with a torque wrench when I put it back
together. I was pulling my hair our for a few days because my tilt
guage sending unit was always getting out of adjustment. Eventually l
realized those bolts had come loose.

Mine were pretty free once they started loosening. I did use the
special star tool and a 1/2 breaker bar. If it turns some but
continues to be "tight" then you need to soak it with any sort of
penetrating oil. Then work it in both directions to loosen the
corrosion. You really do not want to strip out any of the threaded
holes on the outdrive.

It is possible to replace the boots without removing the bell
housing. You will also need a special tool to pull the boots over the
flanges from the inside. I fabricated mine but you can also buy them.