Broken bolt

[Ambush]

I installed a new fuel pump and after some priming it started.

As I was running the eng it would not idle...After a lit bit I see smoke commimg out of a hole in the exh manifold.. Oh no its a missing bolt.

Ok take apart the exh manifold (see pic's) and see the broken off bolt in the head..

I'm not good at removing broken bolts gonna be fun...

Any one, is there some new way to remove a broken bolt?

TIA

[jasoncooperpcola]

My suggestion would be to drill it out and use a heli-coil insert or the like. Or you can drill it out and just go up in bolt size for that hole.

[tsubaki]

I've not bought them yet but there are reverse drill bits available. Basically it drills in reverse helping in a situation like this.
Start spraying with a real good penetrating oil. The best one I've found is made by Mopar.
Drill the hole best as you can in the center, if you get lucky and stay centered and drill to the end of the bolt you can scoot more penetrating oil to the rear. Then use an extractor and hope for the best.
If all else fails, you will have to Heli-coil it.

[Ambush]

Great sugg all thanks...

[spareparts]

left hand rill bit, take your time and center punch the bolt, try as best as you can to get it dead in the center. Start with a smaller bit adn work your way up, as you get loser to the actual size, it may spin whats left of the bolt out.

[Destroyer]

A nice litte trick to use. Since, by the pics, it looks like you have several threads down into the hole before you come to the broken bolt. Take a short, same size bolt (looks like a 3/8 from the pics) and put it into a vise in your drill press. Center punch the bolt in the center, then drill a small (1/8th) hole all the way thru the bolt. Thread the bolt into your engine and using the same drill, drill your first hole into the broken off bolt. The pilot hole will keep your drill bit from walking and you'll get a nice hole down the center of the broken off bolt. Then just unbolt the pilot hole bolt, and start working on the broken off one, either with a left hand drill or using ez-outs or whatever. The real trick to getting the bolt out without messing up the threads in your block is to make that first hole as nearly centered in the broken off bolt as possible.

[steplift20]

funny you should post this cause i just removed a broken bolt just like yours only it was from a lawnmower, what i did was drill a hole in the center of the broken bolt and i used a torque bit and tapped it in the hole you justed made and used a socket wrench to take it out, it worked great but the torque bit has to be a little bigger than the hole so when you tap it in with a hammer its very tight and i would use so me penitrating oil first cause it looks rusty and maybe some heat but i would try the torque bit and go slow when loosing it, please let me know how you made out, i also tried an easy out bit but that didnt work at all and when you drill the hole go at a low speed with the drill good luck

[Ambush]

PLEASE (I don't have a manual)need the torx spesc for the exh manifold, see picture.

Got the broken bolt taken care of and new gaskets so just need the torx spec...


Thanks...

[spareparts]

don't know the exact spec, but usually 3/8 bolts torque to around 30 ft lbs, with that long of a bolts I estimate not quite farmer tight, but not as loose as city boy loose

[twhrider2]

Spare is right on ...specs give 25 ft lbs. Just did mine.
By the way a Hello to ya as we are practically neighbors, I'm in Asheboro. And good luck.