Broken bolt removal! Help!!

[Cheesemaker]

Help!  Where's Mark?  I broke a bolt in my intake manifold.    The one that the support bar goes to, (the other end goes to the motor mount bracket)  to help support the intake runners.  What's the easiest way to fix this dilemma?  I've dealt with the old eazy outs, and have had no luck with them.  Any experience with some of the new style of eazy outs?  Or should I drill out the broken bolt and the old threads and tap in some new threads with a slightly larger set of threads? 

I've been really lucky up to this point and this is the only one that has broke.  I've been using Never Seize on all the bolts to help prevent corrosion or rust on them.  Some of them have some corrosion starting and I've been cleaning them all up before reinstalling them!  To help later down the road if I have to remove them again!

[Wermz84]

If you cant use the easy out, then might i suggest drilling out the bolt center and then tapping it with out making the threads bigger.   

Or if that doesnt work.  drill it out and put a Heli coil in so it is still the same size. 


good luck. 

I know i didn't explain this very well.

[Prismo]

I will usually drill out the bolt VERY CAREFULLY with a size slightly smaller than the edge of the threads. Punch the exact center to start the drill. Peel the rest of the thread out with a small screwdriver, chisel or dental tool. Bend the metal in towards the center from the top as you work your way down. Then retap. I have been successful with this method a number of times. Take it slow as you drill & watch that you do not wander into the threaded portion.

[Tallchevy]

Drill out the center with a small bit. Spray some lubricant  in the hole. Then use a larger left cut drill bit. The left cut bit will grab when drilling & will pull the bolt out. 

[brainlessfool]

well if you have the intake off and there is some of the bolt sticking out you mite try a stud puller on it.

[emsvitil]

Dremel with small carbide tip to grind out.

Takes awhile, but you'll get it eventually (had to do it on exhaust manifold stud)

[Willy Mammoth]

Can you get a picture of the bolt and where it is? It might help pick the best approach.

[brainlessfool]

Can you get a picture of the bolt and where it is? It might help pick the best approach.

X2

[Tallchevy]

If there is enough sticking out, find a nut that will slip over the stud & weld the nut to it & let it cool. Then try to back the bolt off 

[Cheesemaker]

Ok here's the pics Mark.  I'm assuming if I can't drill out the bolt, and save the threads, I'll be able to tap it larger since it's just for a support rod.  It's not holding anything together.  This is on the runners for the first and second runner on the intake!

[Duffil]

that looks close enough, i'd weld to it.

[Willy Mammoth]

If you can get to it with a mig, you can try to weld a nut to it. The heat will help loosen it up and it should back right out. If not you could drill it and use an easyout. I would still at least heat it up with a propane torch to loosen it up first. Just don't burn your house down OK?

[emsvitil]

Afterwards

Larger bolt
or
helicoil
or
threaded insert

Or make an little L bracket that attached to the other nut there and then attach to the bracket.

[Tallchevy]

Afterwards

Larger bolt
or
helicoil
or
threaded insert

Or make an little L bracket that attached to the other nut there and then attach to the bracket.

I would run a thread chaser to clean up the treads & try to use the same size bolt before i would go through the trouble of a heil-coil 

[Cheesemaker]

I'll try a eazy out and heat method.  Didn't think about the propane torch.    Oh, I don't have access to a welder.  That's something I've never really had a chance to learn.  I want to learn how to weld, but after my truck is running! 

[Cheesemaker]

Well, first of all I pulled a brain fart when I started this post!  I totally forgot that I got that efi intake from SNOSHOEBRUE.  And I won't have to tap out that broken stud!  I'll just swap it out!     I was just hoping to pull the whole intake off in one piece and transfer it over to the new motor without taking it all apart!  But I guess I'm gonna have to take it all apart!  I guess it look funny with a air chamber that says "Turbo" on it, when there is no turbo!    This will give me a chance to get all the wiring cleaned up and degreased.  And I can examine all the wiring to make sure none of it is corroded or burned up!  Like my wires going to my coil did! 

[Tallchevy]

 

[Cheesemaker]

Thank you for showing me my way!

I just got so focused on thing that I forgot about the other!

[Prismo]

I was just going to offer you one of my extras when I came back to check this thread. Funny part is, they both say turbo too. Went through the parts shed & found them earlier today.