Thread: OUCH this sucks

Anybody ever tap a broken exhaust manifold bolt out? I know there is the conventional way of drilling and easy out but we are talking a roght iron bolt broken off here...input appreciated.

i believe sears sells a kit to back out the bolts. ive never done it, but i heard those kits makie it pretty easy to get broken bolts out might try thAt

Are we talking about a stud that goes into the head? This can be pretty challenging to extract with the engine in the car, depending on which stud you are working with.

Don't underestimate the value of soaking the bolt with Liquid Wrench or equivalent for a couple days. If there is enough length left, you can lock two nuts together on the stud and try to pull it out this way. Then try a pair of vice grips if you can. Easy outs rarely work in my experience. If there is not enough length for either of these approaches, consider drilling and tapping the remainder of the bolt out of the head.

Good luck with this one.

yeah it broken off in the block and I have the engine out so getting to it is easy. I am going to drill the broken bolt out and then rethread the hole.

Try this first. Get a screw driver or flat-tipped chisel. Hit it straight on into the stud. Then use a screwdriver to turn it out (Use lots of pressure otherwise you'll just strip out the grooves you made). Soak it in some PB blaster or WD-40 for about 5 minutes before hand.

already tried that, not happenin

You are fortunate that it's easy to get to. Start with a small bit that you can control to center the first hole, then gradually increase the size of the bit until you can turn out the remaining threads, or clean them out with your tap. If possible, you can also use a punch to center the first hole as you start. With a good set of bits this should go pretty easily. The key is to center the first hole.

The only thing that concerns me is the fact that this bolt is made of a mich harder material to withstand heat, I don't see it coming out but I will try.

I don't see that you have any options at this point, except to haul the engine to a shop. The metal may not be as hard as you think.

Use good drill bits, take your time, center the first hole, and you should be good.

If you screw it up, you can fall back on a Helicoil insert to replace the orginal threaded hole.
http://www.emhart.com/products/helicoil.asp

Let us know how it goes.

I brought a set of helicoils from the shop just in case, one way or another I will make it work.