turbo exhaust manifold bolts BUSTED!!!HELP!!

[jasoncitrano]

ok, heres the problemo i bought my friends evo III and we were removing it from his car and while we were in the process 3 of the 4 stud bolts cracked, the turbo is off the car now and everything but and the ehxuast manifold is seperated from the turbo but 3 of the bolts are cracked inside the turbo exhaust housing, they are flush with the surface...i was curious what are some methods to fix this? can you drill the threads right out and just use a nut, washer, and bolt set up? will this work? any feedback will help thanks

j

 

[noob-e]

Did you blow the welds and fry the piston rings too, Spilner?


J/K

Sorry to hear that, wish I could help

 

[jasoncitrano]

hah very funny, but no, it's just a pain in the ass somebody else has to have had this problem!! plus is a fresh evo III!!!!! 5000 miles or less on thsi baby just broken in!

 

[91awd]

It's a common problem I have done it before and so have my friends. You have to take them out really slowly and evenly one turn on the back one then one turn on the front one opposite of the one you just did. Anyways I took mine to a machine shop and had them take it out I only broke one and it cost $65. So good luck!

 

[soul]

I broke 3 out of 4 a few months ago when I dropped my turbo for a port/34mm flapper upgrade. Cost me $70 at a local machine shop. They had to helicoil 1.

 

[Generation1JeY]

if you have the right tools lying around, its not the biggest problem to run into. In most cases u just drill the threaded bolt out and with a threading tool u rethread all the broken ones urself. Its not very fun to do, but breaking stud bolts happens too often when working on the turbo or the manifold.

 

[gsxtacy]

I had this same problem 2 weeks ago. My manifold to turbo gasket blew the side out, so I had to remove the manifold and inspect the damage. I broke one of those #8 Stainless 10mm X 1.25 bolts off in my FP Big28. No biggie I thought, just pull the turbo, remove the housing and drill, ease out the bolt, and helicoil any damage. WRONG.

#8 Stainless bolts kick every drill bit I have ever seen's ass*.

I drilled for 3 hours with a craftsman electric drill and specially coated drill bits designed for hard metals and burned about 1/8- 3/16ths" into the bolt and eventually breaking 4 bits that cost near $25.00!!!

I gave up and took it to my machinist friend and had him Carbide Mill the bolt out and helicoil that hole and another that had damaged threads back to the stock thread.

If this ever happens to anyone I recommend letting a machinist repair this.

Exhaust housings are $150-$250 bucks.

Order a new Manifold to turbo gasket.
4 new Bolts from SATAN.
and do it right.

I use Anti-sieze on the bolt threads so they will come out when you need them to.

gsxtacy

 

[Tallen]

Ok. Get some drill bits, start small, finish big. Carbide would be best, titanium will do. Use a punch and hammer to make an indentation in the center of the bolt. Drill SLOW or you will kill the drillbit, use lubrication as well. Use plent of penetratinf oil (PB Blaster).

Use a LARGE easy-out from any hardware or auto store once the hole is big enough. It may come out. Don't push it, if you feel the easy out is bending or flexing...STOP.

Keep drilling and trying the easy-out. Use a piece of ice directly on the bolt to cool it and only it down, it will slightly shrink and often release itself. If not, keep drilling until you can pick the threads out of the hole with a pick. If all need-be, drill it out and use a helicoil.

HAVE FUN!

 

[leet]

I use the method above both at work and at home. If you can't get it by doing that, you are going to have to take it to a machine shop.