Re: 60 hp Johnson 1994 Broken Headbolt

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Posted by Mary ( on June 15, 2005 at 20:35:18:

In Reply to: 60 hp Johnson 1994 Broken Headbolt posted by mark on June 15, 2005 at 18:07:51:

Hi, Had the same thing happen to my Merc 50 hp. If you don't absolutely have to, don't. You can try drilling a small hole in the part of the bolt that is in the head then use an easy out to dislodge it. I have done this before, make sure you have a good drill bit and keep the spot you are drilling wet. WD 40 works good for that. The problem you may come accross though is if it is corroded with salt, if so, it will have to be heated. Heating it is not good if you don't know what you are doing as you can warp the aluminum head.
You should try this, drill a hole in the middle of the bolt, then tap it (thread the hole) to fit a smaller shaft bolt. This is what I did with my Merc - no problem after that.

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