BIG problem with intake install... broken bolt, help!!

GreatWhite

Member

Feb 24, 2006

232

1

17

Fairfield, PA

Aug 7, 2007

#1

• Aug 7, 2007

• #1

OK, so I took off my stock upper and the bolt in front of the #1 cylinder broke off right where it starts to thread. There isn't much sticking out of the block, so what should I do about getting this thing out?

I'm new to motor work so any pointers would be great!

 

4G-KDMP

10 Year Member

Jul 23, 2005

935

19

39

CA

Aug 7, 2007

#2

• Aug 7, 2007

• #2

sorry no real suggestion, but that's gotta suck.

 

5spd GT

"the 5.0 owns all"

Founding Member

Aug 7, 2002

9,516

6

99

Arkansas

Aug 7, 2007

#3

• Aug 7, 2007

• #3

I don't know much is sticking out...but is it enough to get a dremel and cut a slot for a flathead screwdriver and try backing it out?

Good Luck, broken or stripped bolts are never fun...

 

cenok is family

15 Year Member

Jun 25, 2003

1,409

69

79

Norman, Ok

Aug 7, 2007

#4

• Aug 7, 2007

• #4

ez outs. if there's enough sticking out, maybe some needle nose vise grips? just get creative.

 

GreatWhite

Member

Feb 24, 2006

232

1

17

Fairfield, PA

Aug 7, 2007

#5

• Aug 7, 2007

• #5

prolly not enough to get pliers on it... guess i'll have to try to drill it out

 

fastford91

New Member

Aug 15, 2006

254

1

0

Niagara ,Ontario, Canada

Aug 7, 2007

#6

• Aug 7, 2007

• #6

try drilling a smaller hole into the center of it and then use an E Z out! might work if not much is in there!

 

Roland69

Sergeant Tangnet

Sep 17, 2005

2,867

3

58

Port Elgin, Ontario

Aug 7, 2007

#7

• Aug 7, 2007

• #7

I do this almost everyday and almost always works......Place a nut over the broken bolt (make sure the nut is big enough you can see the whole bolt inside the new nut) fill that nut with weld starting the weld on the broken bolt. Let it cool on it's own and with a wrench turn it back and forth and then back it out.....I am telling you if the weld is done right it will work.

If I can't get one to come this way I get my boss to do it ( he is the one who tought me this)

 

V

v8only

Active Member

Jul 3, 2003

2,378

22

49

Aug 8, 2007

#8

• Aug 8, 2007

• #8

it seems to always be that one that breaks.

mine was stuck so solid, no easy out on the planet was going to work. We literally had to drill out the entire thing. By the time we were done, the hole in the head was to stripped to hold a bolt. FYI, if this happens to you, that very first bolt hole on the head overhangs a little, and you can get a longer bolt and get a nut on it from the bottom

 

BlownFiveLiter

have car, will race....wait, it doesn't run

15 Year Member

Nov 29, 1999

3,133

18

108

Chicagoland

Aug 8, 2007

#9

• Aug 8, 2007

• #9

If you can't use one of the above methods for removing it (Ez out, welding a bolt on), pull the head to drill it. They're drilled all the way through as v8only noted, so you should be able to drill it out with a hand drill if you have a steady hand. I did this on a set of GT40P heads I sold that had a broken off bolt, using a bit just smaller than the bolt itself. If you get the metal of the bolt thin enough, it'll come out in pieces and spare the threads. Just make sure you use oil on the bit or you'll dull it out quickly. A local machine shop quoted me something like $40 to extract it, but I wanted to go on the cheap side and did it myself, luckily with no issues.

 

1991vert

10 Year Member

Feb 27, 2004

1,103

7

69

Ludlow, MA

Aug 8, 2007

#10

• Aug 8, 2007

• #10

pull the head and bring it to the machine shop. this is why we never use old bolts.

 

V

v8only

Active Member

Jul 3, 2003

2,378

22

49

Aug 8, 2007

#11

• Aug 8, 2007

• #11

I tried that, and the machine shop refused to drill it out because it was at an angle. They didn't want to chance messing up the hole

 

G

go4it

Founding Member

Jul 15, 1999

206

0

0

Virginia

Aug 8, 2007

#12

• Aug 8, 2007

• #12

Roland69 said:

I do this almost everyday and almost always works......Place a nut over the broken bolt (make sure the nut is big enough you can see the whole bolt inside the new nut) fill that nut with weld starting the weld on the broken bolt. Let it cool on it's own and with a wrench turn it back and forth and then back it out.....I am telling you if the weld is done right it will work.

If I can't get one to come this way I get my boss to do it ( he is the one who tought me this)

Click to expand...

That method works good, we do that a lot on the mining equipment we work on. One of the guys showed me another way because it is hard to weld right down in a small nut sometimes. He welds a flat washer on it first then welds a nut on the flat washer, that way you can use a bigger nut or even weld the nut on the outside. Just thought I would pass that along, might help someone.