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Need help removing broken off studs in a engine bl

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Kevin 1938

07-28-2005 04:30:09




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I am helping a frend remove the front two exhaust manifold stud bolts broken off in the engine head on a 94 Dodge 1500 Van. Both bolts are sheered off even with the engine head. On one of the bolts, a hole was drilled off center and an e-z out was broken off in the hole trying to remove the bolt. Anyone have ideas how we can get the bolt out without removing the head? We have tried heat...we have tried drilling out with a sharp bit...we have tried cussing...we have tried praying...now we are close to crying...WE NEED HELP!!!

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Don L C

08-02-2005 23:44:50




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
This has worked for me...make sure the head is not alummim (good try) .....I weld a good thick strong nut to the broken bolt.....have some one hold the nut over the bolt with a vice-grip..turn the heat up on your elect. welder and carefully stick it in trying to hit the broken bolt...mig works best because you can just close your eyes and pull the trigger.....good luck

Don S.W. Ohio



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Fred Martin

08-02-2005 06:42:32




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
The guys have given you most of the good and accepted methods to get out of your fix. The main thing you have learned is NEVER do it again! The industry uses what is called an EDM machine to remove broken taps, drills and such. It is a machine that heats (arc) and cools (water) and it eats it"s way thru...or kinda disintigrates the bad metal. Be nice to take your head to someone with this machine as they do the best job.

The proper way the NEXT time is to take a block of steel an inch or two thick and drill the tap drill size down thru the center of it in a drill press and then weld a flat piece of metal to it with a hole (elongated) to bolt it down with the nearest threaded hole with the hole centered up over the hole you want to drill out. If you are really careful (read accurate) and use this method...you will have only a spring to uncoil out of the hole...this is the threads that are left. If you have to drill by hand...use a pilot drill of about 1/3 the tap drill size and drill thru...than use a left handed twist drill sized to tap diameter or slightly smaller and drill a with fair amount of pressure and the heat of the drill and the left hand pressure will sometimes screw the broken threaded part right out.

Be sure and wear your safety glasses when you"re doing this type of repair and keep bystanders OUT! Fred OH

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Bill from wisc

08-01-2005 14:28:21




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
I trick I seen that works for me was to heat whats left of the bolt red hot with a torrch then take the heat away and add some bees wax to the area. the wax will work its way down into the threads and once it cools you will be able to turn it out. Its sounds crazy but hasnt failed me yet.



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S. Conner

07-28-2005 19:39:46




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
Take a flat washer the same size as the stud and use a mig welder, not stick, to weld it to the top of the stud. Then take a nut and weld that to the top of the washer. Go take a long break and let this cool down completely. Turn the stud out with a wrench. I've done this several times even with broken EZ outs in them and it's worked every time. I don't even try EZ outs anymore if there is a mig welder handy.

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Ramrod

07-28-2005 14:15:08




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
Over in the 8N forum a new way to remove rusted bolts surfaced recently. Attach your arc welder to the stud or bolt and just let it get red. The bolt will be hotter than surrounding areas, then after cooling, it came out. This might apply to your situation with some modifications.

Ramrod



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bh

07-28-2005 13:27:22




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
I would use the torch and blow out the easy out and bolt. Work slow and careful and you won"t damage the threads much if at all. I"ve used this method many times. I"ve never used the "weld a nut on" method, but I think it will probably work also. Good luck, BH



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Redmud

07-28-2005 10:36:31




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
If you get the easyout removed, drill all the way through to the end of the bolts. then grind off the back side of a new hacksaw blade just enough where it will fit in the drilled hole the full length of the bolt. [larger the hole, the less work with the blade] Do not get the blade hot while grinding, and you want the blade to cut when pushing in. saw through the bolt in two place's, one across from the other, use a sharp pick and a small hammer to loosen the bolt halfs. And a little tape on the blade for a handle helps.

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Bill WI

07-28-2005 08:07:29




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
I would sharpen a small regular masonry bit like a spade drill (cheaper than a carbide spade drill) and get the easy out first. Then drill and get a Heli Coil or equivalent.The threads are likely to be mucked up by the time you get the EZ Out out anyway. Auto parts store should have kits, but they do cost.



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S.Jewell

07-28-2005 07:25:01




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
My dad has torched them out before, you can't cut cast iron with an acetylene torch unless you add steel(rod) while you are cutting. Blow as much material out as you can then re-tap the hole. I would take the easy-out out before you try this. Ah yes the easy-out myth� As you found out easy-outs are not named appropriately, unless the bolt you have drilled out is already loose. I have not personally tried the torch method but dad swears if you are careful it can be done. I had two E-manifold bolts that broke off in my 6.9 diesel. I was lucky enough that I drilled them on center and used a 3/8�s tap and re-tapped the holes. One of them broke loose (actually tightened a little more) while I was tapping it, then I took the �easy-out� and backed it right out. Sorry for the long post:)

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xragman

07-28-2005 07:08:15




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
THis a cast iron head? If so I have blowen them out with a cutting torch. Them chase threads with correct tap.



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Bernie in MA

07-28-2005 05:37:30




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 Re: Need help removing broken off studs in a engin in reply to Kevin 1938, 07-28-2005 04:30:09  
I've removed broken studs this way but they got twisted off by too much tightening, so it may not work for you.

Using a MIG welder weld gobs on the stud until it sticks out enough to hang a flat washer on it. If you have a holesaw you can make a big washer with a small hole. Weld the washer to the stud and weld a big nut to the washer. Use an impact wrench if you have one and rock it back and forth gently. Putting Kroil or even a kid's wax crayon on it as it cools might help too. Good luck. HTH

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fepo

07-28-2005 12:48:09




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 Re: Need help removing broken off studs in a engin in reply to Bernie in MA, 07-28-2005 05:37:30  
I second the MIG method. try welding a small bolt/rod onto the easy out and see if it will come out, use a torch to heat the surrounding area at the same time will help losen the grip o nthe easy out.

then try other methods described to get the broken studs out or retaped. also can try welding a bolt onto the broken studs and see if they will come out...

good luck



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