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Leaking tankless coil gaskets

EJW Member Posts: 321
Once you get the coil out and remove all the broken bolts, throw the coil away, bolt on a steel cover plate and sell them a indirect water heater.


  • Ken C.
    Ken C. Member Posts: 267
    How risky of a repair is this on an older boiler?

    I've seen my share of leaking gaskets on tankless coil covers or cover plates. While I've never replaced one, I know better than homeowners who think the job is as easy as replacing a gasket. A former boss was so wary of this repair that he warned the customer that if the boiler was ruined in an attempt to remove the cover bolts, our company would not be liable. He also said that if you were going to go through the trouble of replacing the gasket, you might as well replace the coil, since the hard part is getting the cover bolts out. As a newbie heating guy, I have several questions related to this subject: 1) Do steam boilers seem to deteriorate tankless cover bolts/gaskets more than hot water boilers? 2) How likely is one to break bolts when removing the cover? 3) What method(s) do you use to improve your chances of removing rusty bolts in one piece (i.e., WD-40, torch, etc)? 4) Do you agree that it's a good idea to just replace the coil, even if the original reason for the repair is a leaking cover gasket? 5) How likely is the boiler block/section to be damaged in the process of removing a tankless coil cover? 6) Do you or the customer assume responsibility if the boiler is ruined during a repair attempt?

  • Risky removal

    These cover bolts break off all the time. Luck of the draw. I've tourched the bolts and hammered on them before I'll lean into them. I still end up breaking off-drilling & re-tapping sometimes. I wouldn't replace the coil unless I needed to. I'd try cleaning the old one first once removed. The customer should assume responsibility if the boiler is damaged during a repair attempt. Make it clear to them how dangerous and time consuming this repair can be. Makes perfect sense to replace the boiler sometimes. Those tankless coils are poor preformers anyway.

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  • sw_2
    sw_2 Member Posts: 6

    we charge $50 extra per broken bolt
  • Robert O'Connor_7
    Robert O'Connor_7 Member Posts: 688
    tankless gasket..

    Yes,Very,(Yes),YES/no,It's likely,customer....Robert O'Connor/NJ
  • Weezbo
    Weezbo Member Posts: 6,232
    Roberts justa bout nailed it:)

    There are tricks to it mind you and some make no sence to the casual bolt twister. enlongating the bolts twisting the heads off of them reamers threaders taps new stainless steel bolts wasters new Brass nuts for the bolts (so the next time the same headache you went through is nt repeated )catapillar no seize...all can easily come into play changing coils...special drills reversing drill bits it is and can be a real experience
    . here is a simple trick tap the heads with a hammer three times get some liguid fire spray around the bolts tap harder on the bolt heads...twist the bolts evenly one at a time a 1/8 turn...spray them all again tap lightly on all of them again then re tighten every single one of them.the ones that now look "Bent" those ,you will likely break the heads off the bolt. clean every thing even liquid fire or wd40 is enough to cause problems...dont even consider putting those bolts back in...new ss studs. clean all the surfaces, it took you all day so you gotta think real clear the next time your boss says something...he is giving you the best advise right from the gate ...
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