Amel Super Maramu 2000

Rebuilding Main Boom Car

Sock each of the 6 bold and nuts on the other side with ZEP 45 and wait

Remove the bold using 5.5 mm socket and screw driver

In reality it was not so easy and I broke 5 bolts.
The bold size was 6-32 x 1" - which surprises me - as it is an Italian product.
The nuts were not 6-32, I suspect they were 3 mm but was not able to confirm Confirm they are 3 mm
I suspect the original bold were 3 mm Confirm they are 3 mm.
If not available, the 6-32 x 1" with approriate nuts will work as well, just a little tighter to put in then remove
In order to remove the bold, I had to tap with a hammer on the back in order to pull them out, then use a wise grip

Then you can remove the top cover (left) and the 2 half bottom covers (right)

The round metal bar holding the shackle will slide out

Received from Amel the new shackle.

Put the shackle on the "shaft" and slide back

There was plastic or nylon washer which I don't have...

Slide the whole boom car on the extension rail

Prepared 1 set of balls, which I divided in 2 groups

With a small screw driver you push them all around the track.

Then the other side, still using a screw driver

Put the cover on top

Put upside down to access the bottom track and start to put the balls.

Then the other side

Put the 2 bottom overs

Put back screw (3 mm x 25) - in my case could not find the philips, the only available were allen head.

Buy spare bolt 3 mm x 25 mm and nuts for the next time it fails

On the bottom, I added Loctite to prevent problem

All 6 back in place

If you are buying the spare (Main or Mizzen) Boom Car, also purchase additional shackle, shipping won't be much more!