Broken studs HELP!!!

[BulletShiftTSi]

I am doing a motor swap on my Talon.

We have the new motor sitting on a palet in my garage as we install all the pumps pulleys belts, new head etc...

Last night I thought I was finally ready to lift the motor into the car and one of the studs that bolts the O2 housing to the exhaust manifold looked unscrewed by 1/2"ish so i went to tighten it all the way back down cause I would hate to have boost leak and the bolt snapped in the O2 housing. So I went to take off the whole turbo from the Exhaust Manifold and loosning the other 3 I broke 2 MORE OFF IN THE O2 HOUSING!

I got only one good bolt/bolt hole in the O2 housing. So I have three broken bolts in my O2 housing. The turbo is a BARLY used geniue evo III 16g zero shaft play.

What are my opitions?
screw out and retap?
replace O2 housing?

someone told me I can't take off the O2 housing without removing my shaft and turbine hotside. and then I have to get it balanced.

HELP PLEASE!

I'll get pics up really soon!

P.S. If I retap the O2 housing doesn't that mean I have to do the same to the Exhaust manifold to make the bigger bolts fit?
Where and what kind of bolts should I get if I retap?

 

[95blackGsTurbo]

There are no threads in the o2 housing. They are in the exhaust housing of the turbo. You need to pull off the o2 housing and extract the broken bolts/studs with an easy-out. You can get them at any hardware or parts store. Then depending on the thread condition you might be able to just install new bolts on all of the holes. If you are talking about the bolts that hold the turbo to the manifold, then it's the same process. The o2 housing doesn't bolt to the manifold so I am not clear on which one's you broke.

 

[fwdmaster]

Just bring your hotside to a machine shop,they can remove your stuck bolt & retap the thread to its original size,I had this problem with my evo 3 hotside when changing o2 housing's also

 

[habitatguy187]

+1. Easy outs are a pain and a lot of times you just end up spending money on drill bits and still never get the studs out. I def. have experience with this one.

 

[BulletShiftTSi]

Sorry I'm not up on EXACTLY what everything is tech called on a turbo.
I mean the 4 bolts that bolt from the top down through the exhaust mani to the turbo.

I'll have a pic up in about an hour hopefully

 

[kristmen]

There is something about all the nickle that's in the metal of the EVO III parts that causes them to melt to U.S. OEM bolts.

I've never broken a bolt off but EVERY SINGLE time I have to remove the manifold, the U.S. bolts come out chewed up, needing to be replaced and the holes in the turbine housing have to be cleaned with a tap.

Interestingly enough, the EVO III does have its own bolts. I've heard from others buying the EVO III bolts fixes the issue.

I finally drilled out all my upper turbine housing bolts holes threads and went to the hardware store and bought some good stainless bolts, nuts and lock washers and just went that route. Nothings actually screws into the housing anymore.

 

[PIMking]

I had the stud break on mine. What a PITA but I broke an easy out so I got her hot with a propane tourch and drilled it out. threads were still good never had a problem since.

 

[LKWTSI]

Sorry I'm not up on EXACTLY what everything is tech called on a turbo.
I mean the 4 bolts that bolt from the top down threw the exhaust mani to the turbo.

If these are the four bolts I think you're talking about, they are just that BOLTS. I just finished replacing my blown turbo with a new Evo III 16g. The bolts your are referring to hold the turbo to the exhaust mainfold. I replaced mine with Chromoly ones from ExtremePSI , when I bought the turbo. They are a pain in a## to get out.

You'll have to get the last one out, hopefully without snapping, and remove the turbo. Then I suggest you take it to a machine shop and have them remove the broken bolts and chase the threads to clean them out. OR if you're really up to it and lucky the bolts may have broken off above the face of the turbo, you might try heating up the face around the bolts and if you can get a good pair of vicegrips on the bolts, gently work the bolt out. The reason to heat up the surrounding area of the bolt and not the bolt itself is the material of the turbo will heat up quicker than the bolt and expand enough to help break the seal. Just don't hold the flame directly on the turbo body for to long as you can damage the face. Of course gobs of some penetrant fluid on the bolt will help as well.

I've had to do it with the every couple of bolts, studs, etc on my turbo swap.

Good Luck.

Also, once you get the bolts out, I suggest getting the Chromoly ones. Like I said mine were from ExtremePSI for $25.00 well worth the replacement over the cost of OEM. They are stronger and if you add the special anti-seize ($1.25) they'll come out better the next time you have to remove your turbo.

 

[BulletShiftTSi]

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I just took these pics it will give you the perfect idea in what I'm dealing with!

Please keep the help/ideas up!

 

[LKWTSI]

Exactly what I said in my previous post. You should be able to heat up around the bolt and get a good grip on the bolts and work them loose. It'll take some heat but don't over do it.

Good Luck.

 

[evileclipse909]

You got lucky there. If you know how to wekd and have a welder available just welt new nuts to the broken bolts. Use lots of penatrating oil and a torch to get them hot. Then work the bolts back and forth till they come out. If you cant weld try vise grips.

 

[BulletShiftTSi]

You got lucky there. If you know how to wekd and have a welder available just welt new nuts to the broken bolts. Use lots of penatrating oil and a torch to get them hot. Then work the bolts back and forth till they come out. If you cant weld try vise grips.

We tried Vice grips on the top left thread in the pic and it wouldn't even budge it just slipped the vice grips.

The other two (top right, bottom right) are pretty much too small to grab good enough with vice grips even tho i didn't try those yet.

They are VERY VERY stuck!

I might take it to a machine shop and they can get them out while keeping the bolt size that same.

 

[Kastigir]

Not sure they will work, but have you tried stud extractors?

 

[spyderturbo007]

I would recommend you take it to a machine shop and let them deal with removing the bolts. I went through this awhile ago and it was a nightmare. Those bolts are really, really, really hard. I went through every type of drill bit on the market and destroyed about 20 of them. I was able to get just enough of a bite on it with an extractor and snapped that off in the bolt.

The guy I took it to said there was no way he could drill out tool steel and ended up removing it with a torch. I guess he was able to melt out most of the bolt and then clean up the threads.

I spent more money on drill bits and hours of aggravation than I would have by taking it somewhere first.

 

[BulletShiftTSi]

The problem is that you can't heat up the housing too much or you could warp it and thats the last thing i wanna do.

 

[Defiant]

Yeah, you wouldn't want the tender little dear to get too warm.