DANGIT -Broken Bolt Help

Cub n M in OR · Jun 5, 2008

I've got a new manifold for my M on its way, so I pulled er into the shop last night to start removing the old decreppid distilate manifold. The first bolt I put my wrench on turned easy, WAY to easy. It was just sitting in the manifold. Who knows how long it's been broken. No real problem getting the other 5 out, but the one farthest forward is broken off just inside the head.
Anyone have any tips or tricks for gitting that stud out? I've got an old set of easy-outs. And have it soaking with penetrant. Just as soon not take the head off and make a trip to the machine shop. If I can help it...

Thanks for the advice!

Ben

Eric in IL · Jun 5, 2008

Some good info here-worth a read.
Recent tool talk thread

Janicholson · Jun 5, 2008

It is 90% likely to not be stuck.
It probably rusted to a smaller diameter, and twisted off. get a 5/16" course thread nut. Make a sheet metal bracket to hold the nut against the spot where the stud is broken, with a 5/16" hole in it over the hole in the nut. A magnet can be used to hold the sheet metal in place holding the nut. Use an arc welder to weld through the nut into the hole onto the broken bolt. (it may be necessary to have a helper turn on the welder while the rod is in the hole)
The weld will not attach to the cold cast iron, it will weld the broken bolt to the nut (and shock treat it to heat). turn out the bolt and grin. JimN

Anonymous-0 · Jun 5, 2008

I would get it out this way:
1. Drill a hole smaller that the diameter of the bolt directly through the center of the bolt.

2. Apply heat to teh broken bolt and area around the hole. Propane usually is not hot enough to do this job, an acetylene torch works best.

3. With everything hot use a squirt can of oil and squirt thru the hole in the bolt.

4. Tap your EZ out into the hole and remove.

5. If the bolt does not turn on the first go, do not force it. Repeat the steps and it should come out

Bob · Jun 5, 2008

DON'T Use a (mis-named) "easy out"!

The only result will be NOTHING (if you give up soon enough). Otherwise, you will be dealing with a broken easy-out.

In my 50 years the only times I have EVER seen an easy-out work is if the bolt is NOT rusted stuck in the hole, only sheared or twisted off, WITHOUT being rusted stuck.

I have NEVER seen a rusted-in-place bolt removed by one of the infernal things!

The "weld a washer to the broken stud, then weld a nut to the washer and allow it to cool before attempting removal trick" is by FAR your best bet.

KEB1 · Jun 5, 2008

If you don't have access to a welder, try a left handed drill bit. Only time I ever tried using an easy-out on a manifold bolt all I succeeded in doing was having a piece of easy out stuck in the hole. Absolute worst scenario, as nothing will touch an easy out. Had a couple broken bolts come right out with a left handed drill bit.

If its really stuck, try drilling it out to where the drill bit is just touching the threads. You should then be able to take an awl or some other sharp, strong object and pick out the remaining slivers of metal.

Worse comes to worse, drill it out & put a helicoil in it. You can get helicoil kits at most good auto parts stores, just follow the directions on the kit. Only problem may be if the hole isn't deep enough to accomodate the helicoil tap.

Good luck, I hate it when things like that happen.

Keith

poorfarmall 1 · Jun 5, 2008

if your good and you can fit the torch in there you can cut it out then chip the rest out

Cub n M in OR · Jun 6, 2008

Thanks for all the advice guys. I'll give a couple of the suggestions a try in the morning and update with my results!

Ben

LN · Jun 6, 2008

drill the bolt through the center , heat area with torch then take a candle and let it melt into the threads take a good quality easy out and try to remove it, have had good success at times with this method

DANGIT -Broken Bolt Help

Cub n M in OR

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Eric in IL

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Janicholson

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Anonymous-0

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Bob

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KEB1

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poorfarmall 1

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Cub n M in OR

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LN

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