Screwed: Broken bolt extractor

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Screwed: Broken bolt extractor

Postby psipwrd » Wed Jul 25, 2012 7:55 pm

I attempted to fix my exhaust leak and made it worse with a bolt extractor kit. The extractor broke off in the block (top right hole). I tried to drill it out over the past two days but only made the hole bigger around the bottom of the extractor. It seems to be welded to the top of the hole.

The bottom stud was previously stripped and a bigger bolt was used instead of a stud. If you can't tell from the pic, the bottom right hole was stripped again while removing the bolt. The bolt was never torqued down good enough to prevent leakage, carbon deposits are all over that area.

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Three things I'm considering:
1. Trying a diamond bur to drill out the top and using a time-sert on both?
2. If 1 fails, use time-sert on the bottom only.
3. Have the car towed to a machine shop.

Open to suggestions. Thanks.
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Re: Screwed: Broken bolt extractor

Postby toayoztan » Wed Jul 25, 2012 8:06 pm

You'll need to fix both in order to get a proper seal without a leak.

If you can't take the head off yourself, I suggest taking it to a machine shop at this point. They will most likely remove the head, and drill out everything and should be able to do this straight on. They might make the hole bigger, at which point they'll use a helicoil or permacoil (my shop used permacoil on mine, very tough). If they drill it out too big, your option is to go bigger on the stud, and would have to drill the hole bigger on the exhaust manifold stud.

At that point, you may as well have them freshen up the head with a standard valve job, get your seals replaced, etc.

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Re: Screwed: Broken bolt extractor

Postby psipwrd » Wed Jul 25, 2012 8:26 pm

:doh: I assumed it would seal as well as the 7 or 8 bolt manifold.

I'm trying to find these to avoid drilling the manifold if I do it myself.

http://www.6gc.net/forums/lofiversion/i ... 80504.html
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Re: Screwed: Broken bolt extractor

Postby toayoztan » Wed Jul 25, 2012 8:38 pm

I didn't think about that, didn't occur to me you had the 9 bolt design.

The 7 bolt design works, but toyota switched to 9 in 92-93, not sure why (if it really was that much better or not).

Most manifolds are designed as 7 bolt though, so you should be fine if you can get that bottom one secured and tight properly.

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Re: Screwed: Broken bolt extractor

Postby CMS-GT4 » Wed Jul 25, 2012 8:54 pm

Last extractor I broke was removed by a carbide dremel bit. It took some time, but it ate the extractor pretty well.
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Re: Screwed: Broken bolt extractor

Postby awolo » Wed Jul 25, 2012 9:03 pm

Just went through all this man. I KNOW HOW YOU FEEL!!

Only my engine was still in the car.

I broke two of those exact extractors! They are junk!
I ended up using the Left handed drill bit method, matched with a screw extractor that was actually worth a da*m.
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Screwed: Broken bolt extractor

Postby celigts » Wed Jul 25, 2012 9:19 pm

So if the exhaust manifold stud lets say is stripped. Don't re thread it go bigger with helicoil or just get a bigger stud?

What about just putting a bigger bolt rather then a stud?
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Wed Jul 25, 2012 10:20 pm

Thanks, I'll order some carbide bits and try to get the extractor out.

Last owner used a bolt instead of a stud. Now that I think about it, I'm glad I was able to pull it out by the head. Now that I ordered a perma-coil kit, I'm wishing I just got the 12mm tap to use two 12mm bolts.
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Re: Screwed: Broken bolt extractor

Postby toayoztan » Wed Jul 25, 2012 10:46 pm

If you can salvage the original threads, chase them with tap (come in the tap and die sets).

If it is FUBAR, then buy yourself a Perma-kit, it'll have the approrpate drill bit in there along with the tap you'll need to create the threads for the perma-coil.

This way, you get to retain your original size stud, and if something happens, more than likely the perma-coil will get messed up, and perhaps living you the last option go use a bigger stud or that one stud offset like you showed.

I've never had a permacoil break on me. Then again, I've never stripped or ruined threads before from putting in a fresh bolt or nut, only b/c it came that way (rusted, couldn't get it out, etc).

When doing any work on any part of the car, ext, int, motor, etc. I always take the 2 seconds to inspect the bolt/nut/stud to see if it's worth buying a new one or possibly end up in more headache.

(I'm not saying it's your fault, but just digressing!)

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Re: Screwed: Broken bolt extractor

Postby Rpz123isme » Wed Jul 25, 2012 11:27 pm

weld a nut on and the heat will help when removing! works everytime
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Re: Screwed: Broken bolt extractor

Postby underscore » Thu Jul 26, 2012 2:58 pm

whats the purpose of using studs anyways? my far left stud was broken when I got the car, it was replaced with a helicoil but removing/installing the stud a couple times killed the helicoil. Should I say forget it and get an oversized bolt, or try a permacoil?
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Re: Screwed: Broken bolt extractor

Postby Hotrodhendrix » Thu Jul 26, 2012 4:17 pm

I had one fubar on my. While manifold was off toss on a nut then toss another one on after. Grab your wrench and go at the first one. I also used a blow torch to heat it up as well. Worked for me and only cost two nuts. Bhahahaha I haz jokez.
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Re: Screwed: Broken bolt extractor

Postby alltracman78 » Sat Jul 28, 2012 4:42 pm

underscore wrote:whats the purpose of using studs anyways?

They grip better than bolts.

That's why people use head studs instead of head bolts.

Incidentally, it's easier to line up something with studs than with a bolt, and removing a nut from a steel stud usually causes less damage than removing a steel exhaust bolt from aluminum.

When you have a stud break, heat the SHIT out of the aluminum around it and melt parrafin wax onto it.
The wax gets sucked into the gaps between the stud and head and it will come out much easier than just with heat alone.
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Re: Screwed: Broken bolt extractor

Postby underscore » Sat Jul 28, 2012 8:56 pm

Good info, thanks. Cause getting the mani/turbo/dp to line up with the oil lines & studs at the same time was a PITA
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Thu Aug 02, 2012 7:30 pm

I can't get the extractor out, the diamond burs would take weeks. Good news is the perma-coil kit went in as easy as 1-2-3 so I'm hoping to get a good seal w/o one bolt.
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