How do you repair broken intake manifold bolt on Merc 496
04-24-2006, 01:13 PM
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How do you repair broken intake manifold bolt on Merc 496
I broke off one of the very small diameter intake manifold attachment bolts on a 496HO. It is broken off flush with the cast iron head and looks too small diameter for an EasyOut.
Any suggestions what might work to reclaim that bolt position?
Any suggestions what might work to reclaim that bolt position?
04-24-2006, 02:42 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
If you know someone who can TIG welding you can weld a little smaller bolt to the broken bolt end. The very local heat from welding will help loosen the bolt in the head and you can turn the bolt out easy.
04-24-2006, 02:50 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
Originally Posted by fbh-velocity
If you know someone who can TIG welding you can weld a little smaller bolt to the broken bolt end. The very local heat from welding will help loosen the bolt in the head and you can turn the bolt out easy.
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Re: How do you repair broken intake manifold bolt on Merc 496
04-25-2006, 12:41 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
if you can drill an 1/8 inch hole in it snap on has the best screw extractor set ive ever used.
04-25-2006, 12:53 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
Originally Posted by ratman
if you can drill an 1/8 inch hole in it snap on has the best screw extractor set ive ever used.
04-25-2006, 03:18 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
Originally Posted by ratman
if you can drill an 1/8 inch hole in it snap on has the best screw extractor set ive ever used.
04-25-2006, 06:44 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
rage, the snap on set has a dowel with little pointed ridges that run length of the dowel, you drill the correct size hole then drive the dowel into the hole and a nut with internal notches slides over the dowel and you put your wrench on this, to back it out of the hole, be sure to use a center punch to locate the hole you need to drill, good luck
04-25-2006, 07:18 PM
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Re: How do you repair broken intake manifold bolt on Merc 496
Originally Posted by fbh-velocity
If you know someone who can TIG welding you can weld a little smaller bolt to the broken bolt end. The very local heat from welding will help loosen the bolt in the head and you can turn the bolt out easy.
Make sure, that before you try this, to unhook any electronic connection to the computer as well as the engine ground cable. Computers and sensors don't like the voltage spikes that are generated by the welding process and can be ruined. as can any other electronic accessory on the boat.
