How could this happen ?

[Spark66]

I have a 2004 df-140 outboard motor.
After motoring out to my fishing hole,
all is perfect with the motor.

When i tried to put the motor back into forward gear,
i hear a terrible clunk / grinding.
Shut the motor off and attempt to turn the prop by hand in neutral
and can feel some resistance.

After getting back on the trailer,
i pull the prop off to find a corroded broken piece off bolt behind the prop.

after pulling the lower end off.
I see the rest off the bolt up inside of the exhaust / water passage.
there are 8 bolts that bolt the oil pan section and engine holder together.
all the other 7 bolts travel thru the sleeves in the casting, but this bolt travels thru the exhaust passage un sleeved .

this bolt dropped down thru the exhaust passage ,
all the way to the prop..

why would any manufacture have a bolt run thru the exhaust / water passage ?

and how do i get the remaining section of the corroded bolt out without drilling it ?
it appears to be the remains of a # 10x160 bolt
Thanks in advance for any input..
Spark

[Spark66]

this issue is 1 bolt in the wrong place from the manufacture and will not come out.
and has been blasted for 5 days ,and the remainder of the bolt will not come out..
i have the 15 dollar replacement bolt 10x160

i cant believe that 1 bolt from the manufacture is keeping me from enjoying my motor and boating pleasures..

[bezerk]

bolt does not go thru exhaust unsleved .you have major corrision on the engine holder ,do you change the zinc's in the power head ? flush motor after saltwater use ??

[Spark66]

boat, trailer, and motor is flushed with salt away every trip as soon as it hits the trailer.
the only corrosion is the bolt !
the rest of the inside is in mint condition.
yes all zincs are fresh.
thanks Bezerk for the input,
but there is no sleeve on this 1 bolt .
and it is the only bolt that passes thru the passage.

[cardy1]

spark66,
Looking at the metal plug just above the flush port on your engine i suspect you do have a corrosion issue. If you are not aware google "suzuki engine holder corrosion". It affected among others, your yr. engine.

[bezerk]

bolt does not go thru exhaust unsleved .you have major corrision on the engine holder ,do you change the zinc's in the power head ? flush motor after saltwater use ??
this is the answer like it or not .

[Spark66]

Turns out you guys were right on the money.
After reading all topics related to the dreaded
Suzuki engine holder corrosion .
Finally decided to try to replace the steel plug with the **** plug.
The steel plug came out very EZ because there where no threads left anymore.

Took it in to the shop to have the Engine holder replaced and
will update with pictures asap..

Anything else corroded such as oil pan ect.
will have to be replaced also.

[Spark66]

well here is an update of the engine corrosion.
take a look at the inside of the holder.
Resized952016121395145513.jpg

original holder. vrs new holder

[Spark66]

pictures will not upload .
I will try again later

[Solarman]

Pics came through fine spark66, it appears the new holder has a bolt hole location that your old holder doesn't have? I'm guessing this is the bolt you found in the exhaust. Great pics.

Good luck.

[Spark66]

yes it is Solarman,
got the new holder installed , with all new gaskets and seals,
oils and lubed.
she purrs on the hose .
after the rain stops i will take her for a good ride.
check oil, drain and replace it again.
Thanks for the help!

[Spark66]

well the motor ran great on test run...
but now have a new water in oil issue.

[barrell]

bolt does not go thru exhaust unsleved .you have major corrision on the engine holder ,do you change the zinc's in the power head ? flush motor after saltwater use ??

Ditto- thats what I was about to ask. When did you last change the zinks in powerhead?