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  #1  
Old 07-24-2012
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Broken brass/bronze fitting. I'm stuck...

On the fuel pump side of my Yanmar 2gm20f there are two valves (or petcocks) for draining the antifreeze.
The lower one was leaking. I attempted to remove it so I could replace it.

Of course you know what happened next, I broke the threaded end off in the block.

Tried an easy out but it won't budge.

Wanting to sail and needing to motor out, I did try putting a self taping screw in with some epoxy and it did not leak, though I didn't run the engine up to full temp.

I have not yet tried heat because the fuel pump and lines are right next to it. I'm afraid of damaging something with a torch and I'm not sure it will help anyway.

The fitting was brass or bronze pipe thread. Any suggestions?
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Old 07-24-2012
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Re: Broken brass/bronze fitting. I'm stuck...

What I would do is to drill it out as carefully as possible, trying to stay within the confines of the threads. Then, using a tapered tap, retap the opening to the original thread size. It's a bit tricky and tedious but I have resorted to that on my older A4 and was successful on three occasions with water pump bolts that snapped off flush with the block.

Good Luck,

Gary
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Old 07-24-2012
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Re: Broken brass/bronze fitting. I'm stuck...

I should have mentioned, there is very little room to work on the side of the engine.
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Old 07-24-2012
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Re: Broken brass/bronze fitting. I'm stuck...

Clean it out well. Plug it with JB Weld. Forget it and go sailing.
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Old 07-25-2012
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Re: Broken brass/bronze fitting. I'm stuck...

Well if you are afraid to heat the area around the fitting, you could try freezing the fitting with liquid nitrogen before trying the easy out again. Just pick up a wart removal kit from the drug store. It's worth a shot!
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Old 07-25-2012
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Re: Broken brass/bronze fitting. I'm stuck...

Have you tried a screw/bolt extractor? Extractors have reverse, tapered threads and are no larger than a tap, so it might be small enough to fit in your tight working area. Normally you would drill a hole in the screw/bolt and then thread the extractor into it. Since you already have a hole in the remnant, you are already half way there. Pick the extractor that's the right size for the hole you already have.

If the material is brass, it may be a little soft for an extractor to work but if it is bronze, it might. If I were in your shoes, I'd soak the area with PBlaster for a while in the hope that it soaks into the bimetallic corrosion area, then try the extractor.

If the extractor does not work you can then do the drill out routine others mentioned earlier.

Good luck, Rob!

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Old 07-25-2012
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Re: Broken brass/bronze fitting. I'm stuck...

@ Caleb, I am considering a fix like that, but, it's the part that drains the old coolant so it would limit my ability to maintain the fresh water side properly (or I could just remove a hose someplace I guess

@ Schock, I'll give it a shot!

@ Dacap, I have tried the threaded extractor, it's in tight but I can't get the broken bits to back out no matter how hard I pull. I feel I'm just going to break off the extractor.

I'm gonna try Kroil or PBlaster for a few days, then the liquid nitrogen

I did speak to a machinist. He said that the dissimilar metals have probably bonded. The only way to get it out was lots of heat, to drill it or make the hole big enough to get a tiny metal saw in and cut it out (probably take hours or days), or drill and re-tap. He did say to try PBlaster but that it probably won't be able to get in there because of the bonding.

The good news is that the extractor ("eazy out") has sealed the hole and does not appear to be leaking any antifreeze....lol
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Old 07-25-2012
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Re: Broken brass/bronze fitting. I'm stuck...

You should be able to nick the brass with small metal cutting blade from a jig saw. then carefully pry the brass inward. (almost the same as replacing a cutless bearing but much smaller of course. Plumbers and pipe fitters do this often with broken pipes. Warning, the thread may be metric! Get a new drain from yanmar. You could maybe even find a large self tapping bolt with rubber and metal washers to seal it. there used to be something like that available at plumbing supply houses.
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Old 07-25-2012
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Re: Broken brass/bronze fitting. I'm stuck...

Quote:
Originally Posted by deniseO30 View Post
You should be able to nick the brass with small metal cutting blade from a jig saw. then carefully pry the brass inward. (almost the same as replacing a cutless bearing but much smaller of course. Plumbers and pipe fitters do this often with broken pipes. Warning, the thread may be metric! Get a new drain from yanmar. You could maybe even find a large self tapping bolt with rubber and metal washers to seal it. there used to be something like that available at plumbing supply houses.
Thanks, I already got the replacement parts from Yanmar, of course they are not the same as they realized their error and retrofitted with a stronger part!

I may just seal it up for the summer and deal with it over the winter.
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Old 07-25-2012
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Re: Broken brass/bronze fitting. I'm stuck...

Just leave the broken threaded end in place and tap the hole in it for a smaller plug. That original bronze threaded end isn't going anyplace. And if you clip the female threads in the engine block while trying to cut it out, whatever you put in there will always leak.
When you need to drain the antifreeze, you can just pull the smaller plug back out. But use a brass capscrew or plug, and not a steel one, or that one will bond in place too. And use some anti-sieze compond on the threads.
All due respect to JBWeld and it's adherants (pun) but I wouldn't trust it to keep the antifreeze in your engine.
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