Bad, bad things.

[Rix86]

Doing the manifold gaskets and such. 3 of the longer center bolts and one shorter one broke just under the surface of the manifold.

I'm now stuck with a manifold that won't move.

Bolts are corroded to the manifold quite badly.

Anyone have a good way to deal with this?

[TerryW]

All I can think of is to use loads of releasing fluid applied twice a day for a week. Then maybe heat the manifold up and tap it around using a copper hammer until it frees from the bolts. Releasing fluid is not very effective but you are in a bad place. Once the manifold is off you can use mole grips on the broken bolts to turn them out. It should work. I just hope you can do it without damaging the head.

I'd avoid jamming anything metallic between the manifold and head for the sake of the head. Any damage that needs doing should be on the manifold.

I am presuming that there are no more bolts holding the manifold on.

[Rix86]

That's kinda where I'm at. The galvanic corrosion has welded the things together. I may end up drilling as best I can.

Things like acid and electrolysis keep coming to mind.

[Rix86]

GUess I'll commence drilling tonight.

wish me luck,...

[TerryW]

Watch out for your knuckles and post your results please.

[Rix86]

This is not going well. Manifold is trash. Gotta find a replacement. Still working on getting it off.

[TerryW]

Wow! That was really rusted on.

[Rix86]

Galvanic corrosion welded the bolts to the inside of the bolt holes. For the entire depth of the manifold. Turns out part of the inside of the manifold was broken anyway.

But this isn't easy.

[Rix86]

There's a couple on ebay....but they have one more bolt hole than mine.

[Rix86]

Hollow victory



Block has the extra bolt hole. Head has the extra boss for the bolt hole. But there's no hole in the manifold.

The remainder of the bolts came out quite easily.

2 of them came out by hand.

[Rix86]

Got manifold

Got bolts

Got gasket kit

Got thermostat

Got broken pistons. Dammit.

I approached this thing all wrong.

Disregarded everything I know about engines because its a boat engine, not a car.

Well..... Now I'll get to pay for it.

Looking at pistons currently. Wiseco maybe.

[Rix86]

Got a replacement engine. Have to swap stuff over from my hell drive to this, which was an outboard.

In the process, found #4 piston broken.

Kinda hate force right now.

[Download_Complete]

Okay, hold up....what boat is this again and what engine/drive?

ANd before you start shopping pistons, let's figure out what you have...and if it's worth rebuilding.

[Rix86]

Its a 120 force outboard power head. Old one is a 120 l drive. The blocks look identical. I gotta pop the new one apart and double check, which I gotta do anyway to replace the piston.

One piston is already new.

Another hundred bucks or so.

Le sigh.

[Chief_Alen]

L drive, might just be better to switch out the power head .

Your call.