Kohler zinc stuck - best way to remove?

D

DaleM

Member
Aug 5, 2009
690
Mt Airy, MD
Boat Info
340 Sundancer
Engines
Twin 8.1 Horizons
Last year when I checked the zinc in my gen there was plenty of 'meat' left so I put it back. I decided to replace it this year and when I attempted it the zinc portion twisted away from the NPT thread. That leaves the zinc part stuck inside the heat exchanger. It's not just floating in there, it's corroded in there. My question is what is the best way to get that out? I have a feeling my only option is to remote the heat exchanger and drill it out. There is a metal pin sticking out but not enough to get a secure bit with vise-grips to pull it out. Should I use something like PB Blaster to get it started?

Ideas appreciated!
 
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I've got the same thing going on with my Westerbeke generator. Threads came out zinc is stuck in heat exchanger. I was thinking about removing the heat exchanger and then tapping on the remaining zinc. It should come loose. If not I'll be drilling it out.
 
+1 on Happy Hour.

Once you remove the end cap it's easily removed from the inside of the heat exchanger.
I have to do this on most pencil zincs replacements.
 
So the end plate on the HE tube is removable? The end plate would be the round disc? How do you remove it?

Mine is the same way and I thought the HE had to be removed from the gen...

Thanks,
Bennett
 
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Use a punch to tap it all the way in. Then remove the end plate and clean out debris
Click to expand...

If you remove the end plate do you risk damaging any gaskets/orings that will require replacement (just planning ahead on parts)? I think there is only one end cap that can be removed on those heat exchangers. Is that correct? And, if I'm remembering correctly it's on the end opposite of the zinc?
 
I just used a screwdriver to try and break it up and get all the little pieces out.
 
I just used a screwdriver to try and break it up and get all the little pieces out.
Click to expand...

I am not sure how that would work in this case. The way it twisted off leads me to believe it's still pretty intact but just corroded to the inside of the opening. I could see that working if the HE has an end cap. I can't find any images or references that say the HE end cap can be removed.
 
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I did it. First season I had my boat, it has the 5ECD. Went to change the zinc and the end came off with no zinc attached. A small screw driver was able to break it up and allow me to remove it enough to install a new zinc. 3 years later and no issues with it or changing the zinc.
 
A small screw driver was able to break it up and allow me to remove it enough to install a new zinc. 3 years later and no issues with it or changing the zinc.
Click to expand...

I'll have to try that. The wire that was extending down from the zinc (I guess its used to ensure electrical continuity?) I couldn't pull it down/out. I'm not sure how soft it is though.
 
I don't recall there being a wire, unless it broke off from somewhere. I boat in freshwater and change it every other year, it doesn't need it but why risk it breaking off again!
 
Can someone verify that one end of the HE comes off, which end, how do you remove it, and are there any gaskets, o-rings, etc. I will do anything not to have to remove the whole HE.

Thanks,
Bennett
 
Really need a pic to determine what your dealing with....
 
i'll be at the boat tomorrow to launch. I'll nose around the exchanger to see if it has removable caps, etc.
 
DaleM said:
i'll be at the boat tomorrow to launch. I'll nose around the exchanger to see if it has removable caps, etc.
Click to expand...

Thanks Dale. I have looked at mine numerous times, but never with the thought of being able to remove the end cap...

Bennett
 
bbwhitejr said:
Thanks Dale. I have looked at mine numerous times, but never with the thought of being able to remove the end cap...

Bennett
Click to expand...

Bennet - I don't remember an end cap on my 340's Kohler, but my 410's Westerbeke has a removeable end cap...
 
I confirmed today there is NOT a removable endcap on a Kohler 5E generator (at least on my 2004 340). I looked at both ends and they appear to be welded or press-fit on. It seems like the only way to get it out is to remove it intact somehow or to take it off, take it home and drill it out/remove. I can post pictures if folks are interested but there's really nothing to see other than round white metal.

I have a 90* drill adapter that I might see if I can get a hole started for an easyout that I have at home to at least give me a shot at pulling it out without having to pull the HE out. I want to be careful that I don't screw up the threads.
 
DaleM said:
I confirmed today there is NOT a removable endcap on a Kohler 5E generator (at least on my 2004 340). I looked at both ends and they appear to be welded or press-fit on. It seems like the only way to get it out is to remove it intact somehow or to take it off, take it home and drill it out/remove. I can post pictures if folks are interested but there's really nothing to see other than round white metal.

I have a 90* drill adapter that I might see if I can get a hole started for an easyout that I have at home to at least give me a shot at pulling it out without having to pull the HE out. I want to be careful that I don't screw up the threads.
Click to expand...

I had a feeling you would come back with this explanation...I have heard that pulling it is not a big deal and I have new o-rings/gaskets to reinstall with. My problem is getting to the rear bolts. Like anything else in a bilge....time and patience. Thanks for looking...

Bennett
 
No problem. I've added this to my list too.

I have heard that pulling it is not a big deal and I have new o-rings/gaskets to reinstall with.
Click to expand...

Where did you get the parts?
 
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