Stuck Lower Unit Screw - The Hull Truth

Fred In PSL · 04-05-2009, 02:37 PM

New member here hoping someone can help. I have an 1988 150 Johnson that I cannot get the lower drain screw out to change the lower unit oil. Tried an easy out and managed to break it off and it's stuck. Any suggestions? Can the drain & fill be done somehow from the top?

davidkuhlmann · 04-05-2009, 02:42 PM

Try a hammer and a punch. You need to get it out.

ShellbackCVA59 · 04-05-2009, 03:05 PM

If the screw slot isn't completely buggered up, try a hand impact driver.

Fred In PSL · 04-05-2009, 03:07 PM

Thanks for the quick reply, problem is, now I have the easy out piece stuck in the screw head, things seem to be going downhill......

AGENT86 · 04-05-2009, 03:46 PM

Quote:

Originally Posted by Fred In PSL

Thanks for the quick reply, problem is, now I have the easy out piece stuck in the screw head, things seem to be going downhill......

Wow. I would have suggested what ShellbackCVA59 said above, an impact screwdriver has saved my azz with stuck bolts & screws MANY times. At this point, if you can't tap it in the direction to loosen it with a punch, as davidKuhlman suggested, MAYBE you can take it to a weld shop and MAYBE they can weld a bolt to the screw without doing any damage to the gearcase. Then, you can hopefully get it out like that??? It's all I can think of at the moment, whether it's possible or not, I don't know.
GOOD LUCK!!!

Fred In PSL · 04-05-2009, 03:50 PM

Thanks everyone, I think my problems may have surpassed my mechanical abilities, probably will have to take it to a shop.......

ShellbackCVA59 · 04-05-2009, 05:37 PM

Maybe with a small die grinder you could grind the slot right threw the easy out?

pilotart · 04-05-2009, 11:20 PM

Spend $25 at an Automotive/Marine Machine Shop for removal.

Next time try this $25 Craftsman (Sears & Roebuck) a 'must-have' tool for Outboard or Motorcycle Maintenance.

seamonster2 · 04-05-2009, 11:27 PM

grind the the extractor smooth buy a left handed solid carbide drill bit while drilling it the bolt will get hot and usually come out if it does not you can get another extractor in and get it out that way or drill out the entire bolt and just rethread and install a heli coil for new plug to fit properly. solid carbide drill bits are only availble at machine shop suppliers

kerno · 04-05-2009, 11:32 PM

I think it is time to remove the lower unit and find a place that does a process called "Tap extraction".

In the machine shop trade, we tap a lot of holes and we also frequently break taps. Like easy outs, taps are very hard and once they break off in the hole, you can't do much but have them removed. Tap extracting is an electrical discharge machining process where the offending pieces are dissolved with a tiny electric arc and the electricity does not care if they are hard or soft. The tap extractor can also get the stuck screw out in the process and it would help if you take a new screw with you so they know what size threads it has. It is not an expensive process and should run you less than $50.00.

renagade69 · 04-06-2009, 06:27 AM

Glen can do it. He is a mobile guy that does stuff like that in PSL. 871-7174 . I have no affiliation to him but he is good with taking stuck thinga apart.

rbhankins001 · 04-06-2009, 06:33 AM

Air chisel. Couple of bumps and it's coming out.

If not do what Kerno says.

Kerno, that sounds really cool, I have never heard of that before.