Broke top off blue drain plug on water pump

Liberty44140

Yep, I did it, couldn’t back out by hand so I used pliers and it broke off. Bummer is that it’s the lower drain hole on the port water pump. I assume I can just drill it out, but what is the easiest way? 3” away from the hole is the stringer so no direct way in. Praying I can do this without removing the entire pump.... suggestions? 

Black_Diamond

Your best bet is pulling the pump. 

You can notch it and use a flat bladed screwdriver to unscrew it. 

When you re-install wipe the o-ring with plumbers silicone grease. That is what usually sticks. Can wipe the threads with it too. 

Ian

Yeah I agree, pulling may be the only way and on a bench and being able to see. I wasn't going to change impellers without taking off and seeing things - as well as the comfort level.

Dream_Inn

Yes, definitely pulling pump is the best.  I had this happen many years ago on my 310, but it was on the thermostat.  Drilling it out carefully was the best option.  You could also change the impeller while you're there and would also insure that you can clean any debris out.

Liberty44140

Thanks gang, I’ll get back out there in the next few weeks and hope to be able to notch and screw it out. Reading some things out there it sounds like the threads are usually not very tight so worth a try, but will bring tools to remove pump and drill. So mad at myself for doing this. Luckily I’ve got spare plugs and a spare impeller to put back in if I do need to pull pump. 

Ian

If I recall aren’t these hollow? Do you have one of those right angled screw drivers? Maybe could you tap a small slot (or philips) screwdriver in what is left and perhaps get enough grip to screw out the remnants of the plug.

Glassguy54

A Dremel tool with an abrasive cut off wheel would get you in there so you could cut a slot in the plug, then use an off set flat screw driver or a flat driver bit in a ratchet handle. Good luck.

aero3113

If you can drill a hole, an extractor set will get it out.

Irwin Tools Hanson 53227 Hex Head Multi-Spline Screw Extractor Set, 25 Piece
https://www.amazon.com/dp/B0002SRG66/ref=cm_sw_r_cp_api_i_5bMPDbAX4JAWX

Liberty44140

@icoultha funny you say that I was just looking at those small right angle screwdrivers at Lowe’s for $3 and there is a small screwdriver Wratchet set at harbor freight for $3. May pick up both!

unfortunately no room for dremmel or drill without removing the pump 

aero3113

No room even if you use a 90 degree Drill?

Liberty44140

My 90 degree drill needs 5ish inches, this is like 3 inches 

Ian

I think your only option before pulling pump is the right angle screwdriver tapped in to see if you can get it out.

zaverin1

Or just remove the lower hose going to the pump

Dream_Inn

I don't know, lots of tight spaces there.  In less than 15 minutes that pump can be out and on a work bench.  Lots easier to get it done then.  It's a total of 3 bolts and two hoses on mine.  

Liberty44140

Agree Dream that removing the pump is not the end of the world. I've done each engine once and it wasnt so bad but I left the hoses attached, maybe its just my setup but getting in there to loosen up the hose clamps on the hoses was not the best angle nor was pulling the hoses off, so I left them on, this was for an impeller change so no issue leaving hoses on. To remove the pump I've got to remove belt, remove idler, loosen fuel pump, move alternator, and then remove the pump....

Ian

With the engine on a rig or with lots of space to work  With mine room is very restrictive plus the hoses are not easy to get to laying on top of the engine and hanging down.

reneechris14

I have way less than there inches can't even fit my fingers in there. When you remove the pump loosing the hoses after it comes of the stud where the idler sits. Just a tought.

earl1z19

For your replacement look at the plugs from Hardin Marine. They are Stainless and wont break off. Well worth the money and never have to worry about breaking them off again

https://www.hardin-marine.com/p-81079-stainless-steel-lifetime-series-sea-pump-drain-plugs-mercruiser-22-806608a02-8m2000874.aspx

Liberty44140

Thanks, I have a couple extra blue plugs so I’m good for now 

aero3113

@Liberty44140 , if it makes you feel any better, I just broke one off of my starboard side cool fuel module 🙄. Luckily it’s right in the front and hopefully it doesn’t give me too much trouble to get out!

Liberty44140

Hey Aero sorry to hear that. Looking forward to hearing how easy it is for you to back out by hand with a screw driver rather than having to drill it....

davidbrooks

Heat the end of a small screw driver using a propane torch. Then carefully push it against the center of the plug till it goes in enough to make a good indentation.  Let it cool or assist with water.  When cool you can unscrew it.  

aero3113

I was able to get the broken stud out today but it wasn’t as easy as I was hoping. I ended up having to chisel it out.