i didnt even need to replace those, but i just couldnt resist to keep them untouched while i was doing full coolant system overhaul.
Yes i saw Grant saying that some will snap and if not it will be my luckiest day.
I got 3 housings off like an easiest thing ever. thought that i won a lottery, until i got to the last RH fron housing
1st snapped
2nd snapped
3rd snapped
4th was going fine untll last 4 mm and snapped

Im buying extractor bits tomorrow, but i really doubt they can do all 4, not gonna try my luck again, what are other options to get it sorted?
please no engine out or welding.

 

Presumably they are snapped off below the surface?

If so I don't see much choice other than drilling and using extractors. Lots of patience, heating and cooling, and penetrating oil.

Tons of You Tube vidoes out there showing different techniques. Everyone has their favorite methods.

Cheers
DD

 

Hi Mouserider

You should have Stopped, as soon as you broke the first one and took stock of what had happened, although of course I guess you know that now

If you had used an Impact Wrench, then there could have been a much better chance of removing those bolts without damage but as it is you've left yourself with a bit of a mountain to climb

Have you got a Photo of those Broken Bolts, as it looks like the only way you are going to get to remove them, is to Weld a Nut on the end of the Stud

I've also tried Bolts Extractors but had no success, although you can get Left Handed Drill Bits, that Drill and Ubdo both at the same time, so might be worth a Shot if all else fails

 

Assuming the bolts have snapped below or level with, the surface, this worked for me:

• Use a pointed sharp punch to meake a dent in the top of the broken bolt
• Buy a LEFT hand HSS drill just a hair smaller than the bolt diameter, or exactly the same diameter
• Carefully drill the hole and the bolt will start to undo as the hole gets deeper, or come out in the form of swarf

Then:

• if the threads are OK in the block, or nearly OK, which they may well be, retap the threads and use stainless bolts to replace the OEM ones
• if the threads are not OK, or the hole is a bit offcentre/bigger than before, retap the hole a bit bigger to take a larger bolt.
• even if the threads are not perfect, as long as you use plenty of Loctite, it will seal any imperfections.

Finally
If you wish to ensure this problem never happens again, you can fit studs to the holes and use stainless threaded rod to make the stud, and fix them in place with the green high temp Loctite that needs a flame on it to get it undone. Then fix the water manifolds on with nuts onto the studs. I have done this on a friends car, when the hole was so damaged getting out the broken bolt, this was the only option.
The only drawback of this method is that you cannot remove just one water manifold at a time, you have to undo both front and back, and lift off both together with the water rail pipe, as an assembly. This is because the studs prevent just one manifold coming free at an angle.

 

thanks! i already drilled a small hole for extractor bit, so anyway will try them first, then if it wont work, will try your method, sounds quite simple and logical!

Thank you

 

I know, i know, but sometimes i do things first and then think. i never use impact wrench on the engine, but i did the mistake, when i was unscrewing bolts i should have screw them in and out while doing so, so oxidation doesnt stack together and then block the bolt, which is exactly what happened. Lesson learned.

I will now try
1 extractor
2 left drill

 

Extractor bits. I have only ever had disasters with them! They always snap off and make a bad situation worse!

 

Yep.

Extractor boys are deadly.

The hole is usually SMALL, so the bit is smaller than the bolt that already snapped. The fact they need to be used in such a manner that actually "swells" the remnants, makes the snapped off bit even tighter in said hole oops. Think about it.

Drill it out, slowly, and breath easier.

Snapping these HARDENED extractors off will ruin more than your day, maybe year.

I dont own any, and never have.

 

If you do use an extractor suggest you use them manually, not using a drill when trying to extract the bolt. That way you can feel if they flex without rotating i.e. indication to stop before you snap the extractor. Drilling and retapping works well. Just remember to use lubricant when drilling and take it slowly. Good luck!