[RESOLVED] Real problem with broken manifold bolt.

[markf671]

As I was replacing my exhaust manifold... I snapped one bolt, it snapped halfway into the hole.... So I searched the forums, ended up buying a extraction bit.. Drilled a little hole for the extractor, tried to turn it,it wouldn't budge! So I bought a the extractor set from autozone did the samething.... I drilled it with a regular bit then tried using the left handed bit... Still no luck! So now I got one side of the bolt drilled out and some of the bolt just hard to get!


I was thinking of just drilling a new hole and tapping it for the new oem stud I bought.... Or can the mess I made be saved? That whole time I was soaking it with PB, how would I go about drilling a new hole? What type of bit do I need? If I go that route.... Any other solutions would be very helpful! I was even thing of towing my car to the machine shop...

Thanks DSMers!
Mark

[AwD4g63TsI]

I would do 1 of two things now that you know an extractor won't work

1. drill out the rest very carefully all the way through, centering the drill as closely as you can. The sides of the broken stud should crumble apart(might need a little coercing with a small pick or something similar). An air gun can blow all the pieces out.
If you are dead set on doing this, you can also take a vary small carbide bit and cut away the inside of the old bolt to try and save the threads on the head.

2. I would recommend this method as it's less hassle IMO. Drill the old stud out with a drill one size larger. Then use a helicoil to get the hole bigger, re-tap, then install the new inserts. You'll be able to use the exact same size stud after this and no trip to the machine shop. You just have to buy the right size helicoil kit. It's very easy to do if you haven't done it before. Good luck.

[markf671]

Thank A lot bro! I will take option #2! It sounds easy enough... Do you know the size of the oem stud by and chance? Thanks again!

[biglady112]

M8x1.25

[markf671]

Thank you so much guys!

[markf671]

One more question? What drill bit do I get? Type and size? Thanks, sorry for asking

[Fejery4491]

Go get yourself some m8x1.25 helicoil. It should tell you what size drill bit to use

[markf671]

Thanks Bro, I finally drilled out that freaken stud... I boought the 8mx1.25 thread repair inserts.. It didn't come with instructions! Do I tap it with a 8m tap? or just insert the new thread?

[markf671]

OK! Thanks again everyone! It was easier then I thought... bolted it up! gonna test it tomorrow for boost leaks! Boom!!!!

[BurrowZ]

Originally Posted by markf671

OK! Thanks again everyone! It was easier then I thought... bolted it up! gonna test it tomorrow for boost leaks! Boom!!!!

Lol.. if your exhaust manifold has a boost leak.. you've got issues.

[markf671]

No leaks! On mani but found a big one on the j pipe.... Fixed now! Thanks guys!