Best method for removing broken bolts?

[slammed isuzu]

Well, we worked like crazy to get the other two out of the left side manifold, with no luck. Broke two ease outs.

New stud/spring kits get here tomorrow. We are going to double check the threads, and then drill/heli-coil them.

....and yes, it is the studs going to the donut flange, not the block.

[slammed isuzu]

Quote: Originally Posted by roademon

i'm assuming yours looks about like this just all of them and not one?

Yes, this looks very similar to what happened to me, except mine was all three.

[roademon]

I wish you the best of luck, after an hour, two broken easy outs, a whole lot of penetrating fluid and half a propane can I gave up and ordered a new manifold lol. The broken stud on mine was previously drilled and tapped and then some oddball bolt shoved in there only to have it shear off so I said screw it haha.

[mesterz2889]

ive done this numerous times weld a nut onto it and do this.



worst case scenario drill it through and weld new studs in from the back

[slammed isuzu]

@roademon-

If it comes down to it, I will order new ones as well. We have a tap & heli-coil set we are going to try out first though.


@mesterz2889-

In my particular scenario, there is absolutely no stud sticking out anywhere, so I would not be able to weld a nut onto the stud. I am at work, on a slow internet connection, so I was not able to watch the video really.....but from what you said, it would appear that I would need some stud sticking out in order to accomplish this...which I dont.

[slammed isuzu]

Quote: Originally Posted by low-s-dime

if the bolts are broken off, just take the manifolds off to get at the unbroken portion...not sure what the issue is here

What unbroken portion are you talking about exactly? As I said originally, they are broken off flush from the "front", and there is nothing sticking out the back hardly at all. Especially not enough to do anything with.

[low-s-dime]

Quote: Originally Posted by slammed isuzu

What unbroken portion are you talking about exactly? As I said originally, they are broken off flush from the "front", and there is nothing sticking out the back hardly at all. Especially not enough to do anything with.

We had a misunderstanding as to which bolts were broken

[slammed isuzu]

Quote: Originally Posted by low-s-dime

We had a misunderstanding as to which bolts were broken

I see. Makes sense then, had it been the ones going into the block...taking the manifolds off would expose (in theory anyways) some portion of the broken bolt to grab onto.

[roademon]

Any luck yet?

[slammed isuzu]

Quote: Originally Posted by roademon

Any luck yet?

Yes and no.....

A guy who runs a local welding shop stopped into my work on Thursday, and I asked him about the manifolds. He told me he could get them out, no problem. He took them over to his shop, and worked on them for about an hour. Called me up and said they were ready.

I paid him $20, took them back to work with me. I noticed that 1 hole, on each manifold, he had ran his tap through, but there was still a bit of the old stud in there, so it created a second set of threads in both of those holes.

I ordered a M10x1.5 tap and drill set to drill those two holes, and tap them to the correct thread size. Should have done it myself to begin with, and saived the $20, but oh well. Lesson learned. Tap and drill set was a little over $7 shipped (my employee price), so I cannot complain too much.

So, as of right now, there are 4 out of 6 holes that are ready to go. Tomorrow by 5:00 PM, I hope that number will be 6 out of 6!!

[roademon]

Awesome! glad to hear it! I didn't have the patience plus I had a mechanic try to fix it to start with and that bolt that was sheared off in mine was way oversized than the stock stud so it kind of past repair even is I was able to get it out.

[slammed isuzu]

Quote: Originally Posted by roademon

Awesome! glad to hear it! I didn't have the patience plus I had a mechanic try to fix it to start with and that bolt that was sheared off in mine was way oversized than the stock stud so it kind of past repair even is I was able to get it out.

I just finished drilling/tapping the last two holes. Threaded the replacement stud in, and threaded in perfectly! I am good to go now!!

I think if I had it to do all over again, I would have just drilled & tapped them to start with, and not even have messed with the ease outs.

[Hoosier Rick]

Drill and tap ftw!

[slammed isuzu]

Quote: Originally Posted by Hoosier Rick

Drill and tap ftw!

After my experiences with this, I definitely agree!!!

[slammed isuzu]

Quote: Originally Posted by roademon

Awesome! glad to hear it! I didn't have the patience plus I had a mechanic try to fix it to start with and that bolt that was sheared off in mine was way oversized than the stock stud so it kind of past repair even is I was able to get it out.

Hey roademon (Heather), you seem pretty familiar with this procedure, would you mind maybe taking a look at a new problem I ran into, while trying to reinstall the intermediate steering shaft?

http://www.s10forum.com/forum/f178/i...6/#post7759644

I appreciate it.