JaSSon00

i was takin the egr off today and the egr bolt that bolts to the header flange broke the head off and left the thread in the flange, as everyone knows im sure (except for 01-02 guys) that this flange is the hardest to get to, well i tried drilling it and barely got anywhere as the bit didnt want to penatrate the steel bolt ( maybe my bit is a pos?) should i go buy a nitride or tit tip bit to drill through it and try and ez out it from the rear??? this is what i was originally thinking but am getting almost nowhere with my current few bits. i tried putting my sheetmetal plate i had made over the flange and tightening it down with the one remaining bolt and used a metal hose clamp to keep the other side tight but still had a leak?? any thoughts??! I dont wanna pull the header if i dont have to. sorry for the long post but i wanted to get some advice so i can knock it out tomm! thanks in advance guys.
Jason <img src="images/icons/confused.gif" border="0">

jmX

I ended up grabbing what was left of the bolt with pliers and twisting it out that way, but it sounds like you might not have that much room.

I'd say give it a solid 30 minutes of messing around, and if still nogo cut your losses and just pull the header.

Next time I have my headers out I'm putting studs in there....no more of this broken bolt crap. <img src="graemlins/gr_guns.gif" border="0" alt="[guns]" />

gwj

If you want one of the quickest fixes (but maybe not the cheapest), get someone to weld a nut on there. Once the nut is welded on, the heat introduced by the welding will usually free the bolt up.

Mark IXZD 150

iTrader: (1)

FWIW, I've seen some special drill bits at Sears that are supposed to remove broken bolts. May be worth taking a look into it.

JaSSon00

i finally got it out. had to drill 2 holes through the bolt to get it weak enoughg to break(drilled a little bit of the flange out too...lol) but it finally broke off after hrs of cussing at the top of my lungs, put a longer bolt back in it with a nut on the back to make sure it doesnt leak. thanks for the help though guys.
Jason <img src="graemlins/gr_cheers.gif" border="0" alt="[cheers]" />

Jax White TA

I did the "smaller bolt with nut on the back" mod to my SLP header EGR flange as well. <img src="gr_stretch.gif" border="0">