Thread: Diverter valve on the Boxxer 421 bolt problems.

I went up to Jondon last week to get some service done on my Boxxer 421 they found something I didn't know about at all. In order to do the work they had to remove the heat shield that surrounds the diverter valve. I thought that one bolt was loose on it and ask them to check it out while they were doing some other work. What they found was that 4 out of the 10 bolts that hold it on had completely come out and were gone! Another bolt was nearly completely out and it was only being held in place by the other 5 bolts. The gaskets or rings had worked loose and it was leaking some exhaust inside the van and not doubt I was losing some heat as a result.

Here is my question. Every single one of the other 5 bolts snapped off when taking them off. Is there anything that can be done to help prevent them from snapping and anything that could help prevent them from working out. I had to replace the diverter valve because I could not get the screws to a machine shop up there and Jondon does not do that kind of work. I've taken some pictures so you can see what happened to it. I plan on taking it to a machine shop and see if they can get those other 5 bolts out for me. This thing cost a whopping $667.12 with tax, shipping, and installation. The part alone was 538.96. I had never removed the heat shield before so I didn't know the bolts had worked out.

Jondon put the new one back just like the old one. I was thinking of either putting locking washer on it or loctite so the bolts won't work out again. Any suggestions?164..jpg163..jpg165..jpg

Since nobody has answered this question I'm bumping this thread. I would strongly suggest if you have had a Boxxer 421 and probably any Hydramaster truck mount that has a diverter valve on it that you regularly check the bolts on them. You may have to remove the heat shield which is 4 bolts to really see what is going on. Your bolts will more than likely work out like half of mine did and unless you have a machine shop handy you won't be able to repair the diverter and will have to replace the whole thing. I will be keeping a close eye on mine from now on. I may call Jondon and Hydramaster about the idea of using loctite or locking washers. Maybe this post will save you the money on having to replace your entire diverter valve. Trust me, if you have one get out there and check that thing out asap!!!!!!!!!!!!!!!!!!!!!!

Thanks, I'll give that a try. I already have a torch and was thinking about that because my brother-in-law suggested the same thing. I still can't believe how much this thing cost. Talk about price shock! I've been told there are similar diverter valves made for automotive use that cost a lot less. I don't see how they can justify 538.96 price tag on this thing.

Wow, my new 421 only has 87 hrs and at 50 hrs (during an oil change) I noticed some loose bolts. That led to finding NUMEROUS loose bolts all over. I didn't remove the heat shield though, so I guess I will tomorrow.
Also, I posted a question lack of water in the gray box (top of machine) in case you've ever had a pump problem or whatever.
Thanks for the headsup.

this will work $175

Is the divertor box made from cast Iron? If so, there are products that can be applied to the threads that will help prevent you from breaking the bolts. It seems to me that since you have dissimilar materials, heat and cast iron that it will lead to the problem. The product I am thinking of is silver in color and can be applied to the threads of the bolts. it is similar to an anti seizure type of product. This works really well especially in a cast iron material.

Like what Gary said. goto the parts store auto zone checker pep boys etc.. get a spray can of PB Penetrating fluid. and antiseize paste.. get Grade 8 bolts from Napa. they will never break. I use them for all my exhaust componants both vehicle and dirtbike or anything with an exhaust.. I am sure the bolts were never torque down from the factory. I can see in one of the pics. the diverter looks as if it was misalligned for some time.

spray the PB onto the bolts that are stuck,, set it overnight or at least 24 hours. you can purchase bolt extractors for the size of bolt you need. for around $10-$20 it does require cutting the bolt flat. using a tiny drill to center the big drill. then you just screw the extractor into the hole, remove it with a good quality cresent wrench or "T" handle. upon reinstalling the higher grade bolts. that will never break!! torque them to about 35 foot pounds. that should be an ideal spec if there is a gasket present. if you need any technical advice look me up. I am a master A.S.E. certified mechanic. it just dont pay well anymore lol