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Tap broken off in exhaust manifold head stud hole...

Posted by 4gfun, Sep 19, 2012

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  1. 4gfun

    4gfun Supporting VIP

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    ....and unfortunately it is the stud that is connected to the oil system!

    Long story but I needed to retap the below hole. I tapped it and when I finished, I went to back the tap out and heard CRACK.

    I have tried to use a center punch and then an easy out, but can't make a dent in the broken tap.

    I am worried that if I drill it out, I will get tons of filings in the motor.

    Do I need to pull the head, or is there another way around it?

    Thanks
     

    Attached Files:

    Street Build 2K  2

    1994 Plymouth Laser RS Turbo
    fwd · manual · 1G DSM

    Street Build 2K  3

    1991 Mitsubishi Galant VR-4
    awd · manual · Galant VR-4

    Street Build 2K  3

    1993 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  2. bryanwheat

    bryanwheat DSM Wiseman

    7,110
    172
    Joined Aug 16, 2004
    Columbia, Missouri
    The only way to get that out is going to be to shatter it with a punch. You will not find a drill bit capable of drilling thru that. If you ran a tap thru the hole than you already have metal shavings in the engine. Luckily it is not a pressurized oil passage. It is only an oil drain passage. You could probably just pull the oil pan and valve cover and spray the oil drain hole down with brake clean to flush those particles out.
     
  3. 4gfun

    4gfun Supporting VIP

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    Ask Me, Virginia
    Thanks for the tip. The problem is getting leverage with that punch, not looking forward to pulling the front condenser, front bumper, etc etc to get a straight shot at it but don't see an alternative. :hmm:
     

    Street Build 2K  2

    1994 Plymouth Laser RS Turbo
    fwd · manual · 1G DSM

    Street Build 2K  3

    1991 Mitsubishi Galant VR-4
    awd · manual · Galant VR-4

    Street Build 2K  3

    1993 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  4. bryanwheat

    bryanwheat DSM Wiseman

    7,110
    172
    Joined Aug 16, 2004
    Columbia, Missouri
    Maybe get a cheap punch and cut it down short so that you have more room. An air chisel would be a good option to try.
     
  5. iugrad92turbo

    iugrad92turbo Supporting Member

    12,273
    470
    Joined May 22, 2007
    Kalamazoo, Michigan
    Sometimes you gotta do what you gotta, moving things you dont want too, pita somtimes.
     

    8K  5

    1992 Eagle Talon TSi
    awd · manual · 1G DSM
    Loading...
  6. 4gfun

    4gfun Supporting VIP

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    Joined Dec 10, 2007
    Ask Me, Virginia
    Good ideas...thanks. Will do what I need to do....hate AC work :) Plus moving that FMIC....on top of it....just venting. :)
     

    Street Build 2K  2

    1994 Plymouth Laser RS Turbo
    fwd · manual · 1G DSM

    Street Build 2K  3

    1991 Mitsubishi Galant VR-4
    awd · manual · Galant VR-4

    Street Build 2K  3

    1993 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  7. SBstar

    SBstar Proven Member

    3,038
    113
    Joined Jan 1, 2004
    Jackson, Michigan
    I'm still a big fan of the welding trick. Have someone or yourself if you know what you're doing, weld a bead out from the stud, weld a nut to that bead, turn it all out. My father-in-law is a pro at it and it literally takes seconds.
     

    5K  7

    1990 Mitsubishi Eclipse GSX
    10.932 @ 123.13 · 1G DSM

    2K  0

    1990 Eagle Talon TSi AWD
    11.146 @ 118.170 · 1G DSM
    Loading...
  8. bryanwheat

    bryanwheat DSM Wiseman

    7,110
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    Joined Aug 16, 2004
    Columbia, Missouri
    That works good for some higher quality taps, but cheaper ones, ive found that it doesn't work real well.
     
    Last edited: Oct 2, 2012
  9. 4gfun

    4gfun Supporting VIP

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    By the way after all of this.....what would happen if I drilled this particular hole too far in and how can I tell if I did? What is on the other side of this hole? I have that to worry about on top of broken tap pieces going into my engine. :)

    Thanks

    I am googling and some people have had luck with carbide dremel bits it seems....supposed to take forever but it is supposed to work.
     

    Street Build 2K  2

    1994 Plymouth Laser RS Turbo
    fwd · manual · 1G DSM

    Street Build 2K  3

    1991 Mitsubishi Galant VR-4
    awd · manual · Galant VR-4

    Street Build 2K  3

    1993 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  10. bjmauck

    bjmauck Proven Member

    203
    1
    Joined Feb 20, 2009
    Augusta, Georgia
    I've gotten them out by cutting an x into the end of a old push rod and working it back and forth.
     

    246  0

    1999 Mitsubishi Eclipse GSX
    manual · 2G DSM
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  11. 4gfun

    4gfun Supporting VIP

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    Should try to get them out with my little snap ring pliers.

    So is it possible/likely to drill too far into this hole and wreck the head???? What do you get into if you drill to far?
     

    Street Build 2K  2

    1994 Plymouth Laser RS Turbo
    fwd · manual · 1G DSM

    Street Build 2K  3

    1991 Mitsubishi Galant VR-4
    awd · manual · Galant VR-4

    Street Build 2K  3

    1993 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  12. wasabi37

    wasabi37 Proven Member

    77
    3
    Joined Nov 7, 2005
    Raleigh, North Carolina
    I had a similar experience a year ago when I took my exhaust manifold out. The stud broke and I center punched it and use the easy out to back it out; however, the easy out broke off on me. So it turned out to be a week long project just using the carbide bid grinding it out bit by bit without hitting the aluminum head. It was PITA but there was no other alternative. :pray:
     

    Road Race Build 939  2

    1995 Mitsubishi Eclipse GSX
    423.8 whp · 378.0 lb/ft · 2G DSM
    Loading...
  13. squeak104

    squeak104 Proven Member

    390
    6
    Joined Mar 16, 2005
    Jasper, Indiana

    494  0

    1995 Eagle Talon TSi AWD
    manual · 2G DSM
    Loading...
  14. safirenside

    safirenside Proven Member

    173
    0
    Joined Jan 28, 2011
    houston, Texas

    541  0

    1995 Mitsubishi Eclipse N/T
    manual · 2G DSM
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  15. bryanwheat

    bryanwheat DSM Wiseman

    7,110
    172
    Joined Aug 16, 2004
    Columbia, Missouri
    The hole goes thru into the oil drain. It is probably an inch past where the threads stop where you could damage the head if you drilled to far. Pull the valve cover off and look at the middle oil drain in the front of the head and you will be able to see the back side of the hole.
     
    Last edited: Oct 2, 2012
  16. NHerron

    NHerron Proven Member

    2,780
    54
    Joined Nov 5, 2011
    Missoula, Montana
    The dremel stones work, not sure on the carbide bits. But I broke a tap off in the turbos hotside once and when I couldn't fracture the tap into pieces, I went to town with the dremel and a stone attachment. Takes patience but you'll be glad when you start to see results. I'd jack the engine up for a little more clearance.
     

    2K  0

    1997 Mitsubishi Eclipse GSX
    11.230 @ 127.000 · 2G DSM
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  17. DSMattitude

    DSMattitude Proven Member

    39
    3
    Joined Jan 24, 2008
    Kalispell, Montana
    If the taps extractor doesn't work I would pull the valve cover and see if anything is protruding on the inside to grab it and turn. Maybe you could get the tap extractor on it from the inside?
     

    1K  0

    1995 Eagle Talon TSi AWD
    manual · 2G DSM
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  18. 99gst_racer

    99gst_racer Moderator

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    Coloma, Michigan
    How in the world does a tap break off in aluminum?
     

    Street Build 7K  67

    1999 Mitsubishi Eclipse GST
    609.8 whp · 541.2 lb/ft · 2G DSM
    Loading...
  19. hretter

    hretter Probationary Member

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    0
    Joined Oct 26, 2011
    Woodbury, Tennessee
    Try the weld a washer,nut trick. I use it all the time for studs with a 110v mig welder, and it works great, although I usually weld a smaller sized bolt and then ratchet the stud out.
    I also had someone weld a tap to a long rod for a special application, so that says to me that tap metal can be welded. Worth a try, seems to me.
     
  20. 4gfun

    4gfun Supporting VIP

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    Thanks all. I really need to learn how to weld....keep saying I will get there but it is time.

    Thanks for letting me know where things lead and your experiences. I'll try what I can out and post the outcome.

    Do you remember which stone attachment BTW.
     

    Street Build 2K  2

    1994 Plymouth Laser RS Turbo
    fwd · manual · 1G DSM

    Street Build 2K  3

    1991 Mitsubishi Galant VR-4
    awd · manual · Galant VR-4

    Street Build 2K  3

    1993 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  21. ramsack

    ramsack Proven Member

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    Joined Dec 27, 2007
    West Lawn, Pennsylvania
    Carbide or diamond is the only thing that is going to eat away at a tap. Even carbide would take forever, as it is even a slow process on a normal hard bolt.
     
  22. honda_burner

    honda_burner Proven Member

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    Joined Jun 25, 2011
    westfield, Massachusetts
    +1 ^
     

    Street Build 1K  20

    1995 Mitsubishi Eclipse GSX
    awd · manual · 2G DSM
    Loading...
  23. ramsack

    ramsack Proven Member

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    West Lawn, Pennsylvania
    You could also try getting it really cold by spraying something like liquid CO2 or liquid nitrogen on it and try shattering it. CO2 might not even be cold enough. Nitrogen, yes.
     
  24. 99gst_racer

    99gst_racer Moderator

    11,780
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    Joined Apr 5, 2003
    Coloma, Michigan
    Most taps are made of high speed steel. Cheaper ones (like what HF sells) are carbon steel. Either will weld fine.
     

    Street Build 7K  67

    1999 Mitsubishi Eclipse GST
    609.8 whp · 541.2 lb/ft · 2G DSM
    Loading...
  25. SBstar

    SBstar Proven Member

    3,038
    113
    Joined Jan 1, 2004
    Jackson, Michigan

    5K  7

    1990 Mitsubishi Eclipse GSX
    10.932 @ 123.13 · 1G DSM

    2K  0

    1990 Eagle Talon TSi AWD
    11.146 @ 118.170 · 1G DSM
    Loading...

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