Starter Casting Busted and Rusted in. How do I get it out?

[Sundancer268]

I have a 1995 230HP 12 Valve in my Motor Home and tried to remove the starter and wound up braking one of the mounting bolts and the starter casting at the solenoid mount trying to remove it. Any suggestions on how to remove it, since Brute Force and Ignorance failed to budge it, I need some other suggestions. Thank you, Ed

 

[3500GMC]

Did/does it have 3 holes in the flange? All the bolts/nuts out?

 

[Sundancer268]

Yes, it has three bolts. One of them is broke off flush with the starter. I did git it out in many pieces. I had my son beat it to pieces and it finally came out. There was a corrosion ring on the mounting flange seizing it to the bell housing and the broken bolt was also seized to the starter flange. I will now have to get the bolt out of the bell housing as I do not want to screw that up. There is an Allison MD3060 transmission attached to it and I do not even want to think of having to remove it. The old TorqueFlight 727 was heavy enough. Thank you for the reply, Ed

 

[bison]

If you have access to a mig welder, weld a washer to the stub and then a nut to the washer,the welding heat often breaks the hold of the rusted in treads.
Give a couple good wacks with a hammer on the nut before trying to turn the stub out.
Use some WW40 and crack the nut back and forth till the stub moves freely.
If the nut breaks off,..do the process again

 

[Sundancer268]

I do not have a MIG, but I do have a wire-feed and was toying with that Idea. I did have the bolt red hot with my cutting torch and it did not move. I am now soaking it in Aero Kroil and hoping it will move when I put some torque on it. I am not going to get in a hurry as I do not have a new starter in hand yet.