Broke Turbo bolt. Help!!

[BoostInsideTSi]

I bought the gasket from slowboy racing for the turbo to manifold, and went to take out the 4 turbo bolts, and the 2 closest to the head broke in half, now they are stuck in the manifold / turbo. I went to a local shop, they are charging 75 per hour to remove them. Don't know if that's a rip off or not. Anyhow, they said I gotta remove the manifold / turbo, and we all know how much of a bi*** that is. Anyone ever have this problem before? What should I do? Any help is really needed. Thanks.
Mike

 

[philipkrotch]

ya, i had it happen to the bolt on the top right corner..it broke off flush with the exhaust housing...i just took a dremel and cut a notch in the top of the bolt, took an impact screwdriver and banged the fawker out.

 

[BoostInsideTSi]

Do I need to pull the turbo / manifold setup or can I leave it in the car?

 

[greeneclipse]

ya....they're probly broken off in the turbo, so you need to take it off and then pull the bolts.

 

[miteclgst]

this just happened to me, two of my bolts got cross threaded in the install, one came out but wrecked the threads in the turbo and the other I had to cut the head off in order to get the manifold off. Once I had the manifold off I retapped the hole that was cross threaded for a 7/16 20 grade 8 fine thread bolt, I did the same thing to the other two holes also, just to keep everything the same. when it came to removing the bolt, I had no choice, I had to drill it out, what a nightmare, those bolts are made of hardened steel and it dosn't even seem like the drill bit will touch it. But as a friend once said, with some time and pressure you can drill through anything. This was very true in my case. What we ended up doing is attaching the manifold onto the turbo and using the hole in the manifold to keep the drill from drifting. A total of 2 hours later, yes two hours we finally had the hole drilled through, this was with really good drill bits and drilling the entire time. I tried to take the turbo to a machine shop and they wouldn't touch it. They couldn't set it up square in their drill press and they said that they would invariably get shavings into the exhaust turbine area. So I had no choice, my advice would be to see if you can get a machine shop to do the work for you, they have really expensive carbide bits that will greatly reduce the drilling time. THe bolts that I ended up using were 7/16 20 grade 8 fine x 3.5" I was actually quite happy with the extra length because it allowed for the install to go a bit easier then the first time around with the regular mitsu bolts. You have to take the turbo out of the car because otherwise you are just looking for problems. There is no way to redrill that hole straight enough working in that tight engine bay.