Yanmar KM4A, how to remove oil cooler?

[Stonemonkey]

It froze over the winter. Cooling water floods into the gear box. I took the box out and open the cooler, looked inside, I don't see cracks on the walls, I assume something is bad at the far end. I'd like to take out the cooler body without damaging it. The manual is short on describing how. Any ideas?

 

[Stonemonkey]

The cooler body (pipe) expanded inside. No way I get it out without destroying it. There are probably couple of mm more all around almost full length. I'll be lucky to get it out without disassembling or destroying the gearbox. I tried to pull it with pliers, not working. Have no idea yet how to pull it out .

 

[Boater Sam]

Lock a couple of pairs of mole grips on it and use a slide hammer to drag it straight out? If it is copper or brass it should pull out.
If not, I would try to cut a line down it inside with a sharp chisel then try pulling again.

 

[Stonemonkey]

It’s brass. Mole grips and hammering out isn’t working. Drilled some small holes on the sides and tried to pull it out hanging it on those, not working. Next I’ll try cutting it down inside with a sharp chisel, then pull it out.

 

[Stonemonkey]

Cutting a line down inside with a chisel wasn’t a breakthrough since it made the extraction impossible because the edges were clinging on everything inside, but after cutting one more line I could start slicing bits of it with a tiny grinder and collect them with small pliers. It was a messy operation that took loads of hours. Trying to bend it towards the middle was a mistake that costed me several hours. It shrink the working space. Finally I got it out and wash the grinding dust out of the gearbox with diesel. Filled the box several times with 1l diesel , shake gently, rotate the shaft in all gears so that the dust deposits on the bottom, drain it out. Fill several times more and suck from the bottom on the drain hole and on the oil cooler hole with an oil pump.

 

[Boater Sam]

Cutting a line down inside with a chisel wasn’t a breakthrough since it made the extraction impossible because the edges were clinging on everything inside, but after cutting one more line I could start slicing bits of it with a tiny grinder and collect them with small pliers. It was a messy operation that took loads of hours. Trying to bend it towards the middle was a mistake that costed me several hours. It shrink the working space. Finally I got it out and wash the grinding dust out of the gearbox with diesel. Filled the box several times with 1l diesel , shake gently, rotate the shaft in all gears so that the dust deposits on the bottom, drain it out. Fill several times more and suck from the bottom on the drain hole and on the oil cooler hole with an oil pump.

Well done, can you do dentistry now?