broken bolts....

**randys626turbo** · 11-12-09, 18:38

alright i took my turbo off because the seals are blown on it, and there is oil all over in the exhaust housing of the turbo, it was bad...haha but i have a broken bolt on the manifold, and the manifold bolts that bolt it to the head, and i wasnt sure on what the best way to get them out was, so i was just wondering if i could try anything to get these out so i dont have any leaks, ill get some pictures of the turbo up soon tho

DiaMagus · 11-12-09, 19:24

Umm if its easy to get to you can prolly drill it out if not. Id say take it off take an acetylene torch and get the manifold hot so it expands and maybe weld a piece on to the bolt to finagle it out.. might work O_O i dunno going out on a limb hope it helps >_<

**randys626turbo** · 11-12-09, 20:39

thats not a bad idea at all i for the manifold to the head bolts would be hard because i dont have a welder here so i might have to take it somewhere and have them do it for me

DiaMagus · 11-12-09, 20:40

Id remove the manifold, especially if you drill. wouldnt want shrapnel getting in to the guides/seats

**randys626turbo** · 11-12-09, 21:44

u think i should just drill it out one size bigger at a time then just tap it out or what

**concealer404** · 11-13-09, 8:26

You mean you broke one of the exhaust manifold studs?

**Mazda Carnage** · 11-13-09, 9:58

Quote:

Originally Posted by randys626turbo

u think i should just drill it out one size bigger at a time then just tap it out or what

No. Get a broken bolt extractor and use the right size drill bit, drill into the broken stud and extract it. they rarely get stuck in the head and usually come out easily.
If your going to drill a bigger hole then use heli-coils, the threads left by your average tap set aren't going to hold the studs.

You can also try a rotary tool (like a dremel) and a small cut off wheel, just cut a grove in the stud and use a flat head screw driver and unscrew it, if this fails use the groove to center your drill bit and try the bolt extractor.

**randys626turbo** · 11-13-09, 10:35

im just going to take it in to a friends shop to mess with the head bolts but i need a new manifold i think because i cannot get the old bolt out of the manifold i broke one that connects to the turbo too...it must have just been soft or something because it just came right off

**automan** · 11-13-09, 14:13

Quote:

Originally Posted by Mazda Carnage

You can also try a rotary tool (like a dremel) and a small cut off wheel, just cut a grove in the stud and use a flat head screw driver and unscrew it, if this fails use the groove to center your drill bit and try the bolt extractor.

Good idea. Make sure you spray Liquid Wrench, WD-40 or similar before doing this. I know from previous experience that some shops will charge many hundreds of dollars to do this.

**chief tool** · 11-14-09, 16:08

Quote:

Originally Posted by Mazda Carnage

If your going to drill a bigger hole then use heli-coils, the threads left by your average tap set aren't going to hold the studs.

As far as the head goes, you must be talking about a very average tap set.....I re drilled mine and tapped them to 10x1.25 and fitted some FE3 studs...there was no issue. Mind you I did mine pre emptively before any of them broke

I drilled the holes slighly smaller than you otherwise would in steel just to make sure it would be ok....I tested it out on an old junk head that I had and it was fine before I did mine one the car.
I loctited the studs in to make sure.

As for removing broken studs in the exhaust manifold where the turbo attaches....I had to remove 3, and I tried every trick in the book to get them out, and n the end had to drill them out....
Problem is that those studs are very hard, and will blunt most drills, and its hard to get a thread extractor to bite into the metal.
By the time you drill a large enough hole to get a decent sized thread extractor in it...you might as well keep going.

Just get another manifold from the junkyards with no broken studs....it'll be heaps easier!