turbo oil return problem

[2gntrbo]

i was removing my exhaust manifold and turbo so i could put in my new stainless steel exhaust manifold studs. i removed my oil return line, that goes from under my big 16G and to the oil pan. i got everthing out except for 1 broken stud. no biggie got it out with an "easy-out". i put my turbo and manifold on the work bench and before i went inside i wanted to put the bolts back in for the return line, well luck have it i overtightened one bolt and snapped it off flush. i center-puched it and tried to drill it out so i could use my easy out but i messed up and i went off centered... sorry so long of a post... What do i do now so that i dont mess any thing else up on my turbo. please chime in with any advice. all will be greatly apperciated
ryan

 

[91 Turbo Mitsu]

Got a welder? If yes then you might be able to weld a nut onto the broken stud and turn it out. If you can go this route just make sure you cover everything so you dont get any weld splatter anywhere in the turbo. This would be very bad. The other trick I have done is to take a cutting wheel and slice a notch in the broken stud then use a screwdriver to turn it out. This usually works well because most of the time there is no tension on the broken bolt unless you boogered the threads. Hope this helps. Travis

 

[2gntrbo]

yah i got a welder but the problem is that i drilled about a 1/8 or so down in to it and that mad it go off centered. my friend said sumthing about a helix coil. let me know what else i could do. maybe i could just drill out the hole and tap so i could put in one of my old exhaust manifold stud in it and nut the stud. im outta idea. thanks for any replies

 

[romeen]

It sounds like you probably will have to drill it out completely and re-tap it. In that case a helicoil will be your best bet but they cost $30-$40 for the kit vs. free for using an old exhaust manifold stud. The problem with the latter is that the studs are 8mm but the stock bolt is 6mm. I'm not saying it wouldn't work, but it wouldn't be optimal. I'd rather use 2 bolts of equal size vs. one 6mm bolt and one 8mm stud.
The helicoil kit you need is M6X1.00. It comes with the tap and usually with the appropriate drill bit, if not it will tell you what size bit you need.
Good luck.

Let me know if you need any advice on the helicoil procedure.

 

[2gntrbo]

sorry for the long reply been down with bad flu. i finally got it fixed i jus drilled and retaped both for one sice bigger bolts thanks for the replys