Broken Intake Bolt Question. New Heads?
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Broken Intake Bolt Question. New Heads? So my problem started when I over tightened one of my intake bolts and it broke inside the head. A local guy was going to bring by his EZ-Out and help get the broken bolt out. He never came by! 
I ended up going to Autozone and bought the EZ-Out and attempted it myself as a friend said to drill straight in the middle. I was not completely sure how to use it but I now ended up just drilling a large hole through the bolt but its still stuck in my head. I have since put the intake back on with the new bolt but it will only go in a few threads as it stops where the last one is locked inside.
My options:
1) Get a cheap set of 806 heads and replace the heads. Is this hard?
2)Upgrade to 241 or 243 heads but buy new valve covers and coil brackets.
I want to make sure nothing happens to my motor since one side of the intake (very front right bolt) is not tightened down. Someone let me know any problems I may face if I don't get this done asap? Thanks
I ended up going to Autozone and bought the EZ-Out and attempted it myself as a friend said to drill straight in the middle. I was not completely sure how to use it but I now ended up just drilling a large hole through the bolt but its still stuck in my head. I have since put the intake back on with the new bolt but it will only go in a few threads as it stops where the last one is locked inside. My options:
1) Get a cheap set of 806 heads and replace the heads. Is this hard?
2)Upgrade to 241 or 243 heads but buy new valve covers and coil brackets.
I want to make sure nothing happens to my motor since one side of the intake (very front right bolt) is not tightened down. Someone let me know any problems I may face if I don't get this done asap? Thanks
if you already have the hole drilled into the broken bolt, the rest should be easy. THe easy out looks somewhat like a tap, but works in a counter clockwise direction. using a tap handle, rotate the easy out bit in the hole until it "Grabs" the bolt.
yeah, dude, if you have the bolt drilled already, its a little more work to get the rest out. Get the ezout, or you can even try jamming a screwdriver into the hole you made, and turning it counterclockwise!
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Whats on the other end of the intake bolt hole? If I kept tightening the new intake bolt down would it push the old bolt out the bottom of the hole?
I wish it was that easy. But without me looking like a total fool.... The center of the bolt is stripped out. As in I used two different sizes of the EZOut and it ended up just making a big hole in the center of the bolt but not big enough to strip the original threads. Im not really even sure how to use the EZ out but at that time I was mad and desperate so i tried it and now its all jacked up.
Whats on the other end of the intake bolt hole? If I kept tightening the new intake bolt down would it push the old bolt out the bottom of the hole?
Whats on the other end of the intake bolt hole? If I kept tightening the new intake bolt down would it push the old bolt out the bottom of the hole?
I wish it was that easy. But without me looking like a total fool.... The center of the bolt is stripped out. As in I used two different sizes of the EZOut and it ended up just making a big hole in the center of the bolt but not big enough to strip the original threads. Im not really even sure how to use the EZ out but at that time I was mad and desperate so i tried it and now its all jacked up.
Whats on the other end of the intake bolt hole? If I kept tightening the new intake bolt down would it push the old bolt out the bottom of the hole?
Whats on the other end of the intake bolt hole? If I kept tightening the new intake bolt down would it push the old bolt out the bottom of the hole?
I tend to tap the EZ out lightly with a hammer to get it to stick. I've also found that the rectangular EZ out bits work better than the drill bit shaped ones.
If tapping on it doesnt help, try to get a left hand drill bit as mentioned above.
I don't remember if the hole is a through hold or not. Is the head still on the engine and in the car, or is it out on a bench?
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Imagine though that you screwed something inside of the hole, now I came and drilled in the middle of the bolt basically hollowing the bolt out. I do not see how I could jam anything in to get it to grab and back out? Surely it is not that easy. I never used too big of an EZout bit to drilled inside the hole so I know I could not have cross threaded it or anything. Easy thing would be to take the new bolt and tighten it down hoping the old bolt could come out the other side.
And the heads are still on the car. I wish they were off, it would be much easier.
And the heads are still on the car. I wish they were off, it would be much easier.
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Verdad Gallardo no, tightening a new bolt would create a jamn nut effect possibly stripping your threads in your head (which would require a helicoil to fix 
)
There shouldn't be too much effort required to unscrew the broken bolt, no thread locker should have been used.
Here are some examples of how to extract a screw:
http://homerepair.about.com/od/inter..._extractor.htm
http://www.asashop.org/autoinc/may2003/techtotech.htm
http://www.newmantools.com/drillout/how1.htm
http://www.motorcycle.com/how-to/how...rews-3440.html
)There shouldn't be too much effort required to unscrew the broken bolt, no thread locker should have been used.
Here are some examples of how to extract a screw:
http://homerepair.about.com/od/inter..._extractor.htm
http://www.asashop.org/autoinc/may2003/techtotech.htm
http://www.newmantools.com/drillout/how1.htm
http://www.motorcycle.com/how-to/how...rews-3440.html
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Great sites ^. I wish I had seen these before attempting this myself. I did not know I had to drill a small pilot hole with the small one then, use a T-handle for the larger of the 2. Or is the larger one then the smaller one? The set I bought was this one from Autozone: http://www.amazon.com/gp/product/B00062ZDF4
I started with the last 2 bits, M5-6 3/16-14. I started to drill a hole in the center with the drill bit then put the extractor in next and drilled counter clockwise but nothing came up so then i went to the next size, M6-8 1/4-5/16 which this did nothing either. I think i stripped it out with this next larger extractor. So what could I push inside the hole now that would lock inside and help back it out? My fear now is that I am too close to the threads so I do not want to use the EZout any more for fear of cross threading the hole.
I started with the last 2 bits, M5-6 3/16-14. I started to drill a hole in the center with the drill bit then put the extractor in next and drilled counter clockwise but nothing came up so then i went to the next size, M6-8 1/4-5/16 which this did nothing either. I think i stripped it out with this next larger extractor. So what could I push inside the hole now that would lock inside and help back it out? My fear now is that I am too close to the threads so I do not want to use the EZout any more for fear of cross threading the hole.
Any way to post a pic of the bolt?
M6 is awfully close to the diameter of the bolt itself, isn't it? I thought those were 6mm bolts. Its been a while since I messed with any of that.
It sucks when they strip out like that, it does happen. You need to be able to get in there deep, but it sounds like you don't have much bolt in there.
The only other thing would be to hammer a junk screwdriver (or allen wrench, or even one of the bigger extractors) until it is tight, then unscrew it with Vice grips or something.
M6 is awfully close to the diameter of the bolt itself, isn't it? I thought those were 6mm bolts. Its been a while since I messed with any of that.
It sucks when they strip out like that, it does happen. You need to be able to get in there deep, but it sounds like you don't have much bolt in there.
The only other thing would be to hammer a junk screwdriver (or allen wrench, or even one of the bigger extractors) until it is tight, then unscrew it with Vice grips or something.
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The bolt is actually a 8mm bolt, positive of that. So the M6-8 means it's for a 6 or 8mm bolt? I hope I did not strip out the threads on the original hole. I guess I can try to hammer in the M8-11 5/16-7/16 extractor, it's the 3rd size up from the smallest. I wonder what will happen if it does not grab. If this fails how would I go about redrilling the hole and if it can not be pulled out what to do next?
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http://www.dsmtuners.com/forums/arti...-helicoil.html
http://www.roadstarmagazine.com/modu...rticle&sid=233
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Interesting! ^ Thanks!
So where do you buy this helicoil set at? And would I be able to use the original intake bolt for the helicoil spring or would I need to find a new bolt? Seems pretty simple, drill out larger new hole, insert helicoil spring inside, and then bolt works in the new spring. Where does all of the other pieces of metal go that I shaved on top of? Isn't the valve just below the head? Learned my lesson. lol
So where do you buy this helicoil set at? And would I be able to use the original intake bolt for the helicoil spring or would I need to find a new bolt? Seems pretty simple, drill out larger new hole, insert helicoil spring inside, and then bolt works in the new spring. Where does all of the other pieces of metal go that I shaved on top of? Isn't the valve just below the head? Learned my lesson. lol
dang bolt! In my experience with a broken bolt if the ez-out didnt get it, i would keep drilling the bolt out with larger drills up to the point of drilling the aluminum head - with re-trying the ez-out at each step up. if that fails a Heli-coil -available at most auto parts should be bought- about 25$ for a kit-should include the proper size drill and tap(maybe not the drill) - drill the hole with the proper size drill then tap the hole - blow out the chips and use the plastic install tool to thread the Heli-coil into the new hole and you should be ready to install the new bolt. the drilling out of the hole usually releases the grip on the old bolt as what is left of the bolt is removed by the drill- all in all shoud be allot easier than replacing the heads. good luck!
One question, are you sure it is the intake manifold bolt that broke off in the head, and not an actual head bolt or rocker are bolt in the head?
I remembered my old thread about making pseudo alignment studs when port matching a fast intake: https://ls1tech.com/forums/generation-iii-external-engine/525974-fast-90-intake-owners-have-you-tried.html
and I do mention the thread being 6mm
I think the small head bolts are 8mm in diameter (could be wrong, doing this frommemory) as are the rocker bolts. A picture would help.
I remembered my old thread about making pseudo alignment studs when port matching a fast intake: https://ls1tech.com/forums/generation-iii-external-engine/525974-fast-90-intake-owners-have-you-tried.html
and I do mention the thread being 6mm
I think the small head bolts are 8mm in diameter (could be wrong, doing this frommemory) as are the rocker bolts. A picture would help.
