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2012 LSV 6.0 muffler removal

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Hello Malibu owners, 

Sometimes I think I have the worst luck. Went to replace the impeller on the first day of vacation, and broke one of those damn brass bolts in the impeller housing. Its impossible to get to with an extractor while on the boat, so I need to remove the pump, but cannot get to the Allen bolts with the muffler in place. I have released all 12 c-clamps to the muffler but cannot get it to move - is there something I am missing, or do I just need to get a big pry par and force this thing off the attached hoses? Any help/advice would be appreciated, TIA! 

Edited by MykP
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Ahhh man, that sucks! Do you need the extra room so the puller fits? You can get the impeller out other ways.

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Posted (edited)

I replaced the impeller no problem, I need to extract a broken screw in the actual housing. So, the only way I can see to do that is remove the muffler, but I cannot get the muffler out. Any thoughts on how to get the muffler loose? Bolt broke when I was reinstalling the cover

Edited by MykP
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The screw shouldn't be under tension at all.  You may be able to back it out with just pressure from your thumb.

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Is the bolt sticking out at all?  When those break they are typically not tight in the housing and you can just use something like the eraser end of a pencil to twist them out.

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Thanks guys for the ideas here. Unfortunately none of the bolt is sticking out, it’s just under the surface of the housing…however the pencil eraser idea is great one…I’ll give that a shot today! I hate to remove the pump if I don’t have to…

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