Broken Lower Unit Bolts.

[Houseboy22]

Hello all. The end of last season, while draining the lower unit, it became obvious that it was time to do a seal job on my 1988, Johnson, 50 hp, 2-stroke, 2-cylinder outboard. While attempting to remove the five lower unit bolts, I managed to twist the heads off of two of them. While this did allow me to remove the lower unit so I could install the new seal kit and water pump kit, it leaves me with two small problems. Because about three eighths of an inch of each bolt still protrude from the upper unit, I've got a plan in mind for removing them with some heat and a small pipe wrench. My questions for the Johnson pros are three. First, is there a prefered method for removing these broken bolts, second what are the part numbers for the replacement bolts and third, is there a recomended anti-seize product I could use on the new bolts?

Thanks for your help and this site.

Sincerely,
Dave

[boats.net]

You can take it to a dealer or welding shop, they may be able to weld a nut on broken bolt and remove it without any problems. Yes use anti-sieze or grease on all mounting bolts and grease on drive shaft splines.

[gottmoore]

Is this in salt water use? If so, it has happened becasue of a build up of salt. You do need to use sealing compound when you get them out and go back, OMC gasket sealing compound is a great one to use.

I know the feeling of I got it, I got it, oh no! Believe me, when you try this trick you will kick yourself for not using it before. As you mentioned Heat it up prior to unbolting, I mean REALLY heat up the bolts, till they change color. The will back out like nothing. ITs truly amazing.

To get the stubs out, try the weld on solution above or try a pair of vice grips after you heat. If you can't get vice grips on, try taking a hacksaw blade, and cut a groove to get a straight blade screwdriver on it. Believe me, it wants to come out, you just have to get all the salt out that is binding the threads.
Good luck