You can use anti seize if you want. Just get the same size bolts from Home Depot and use hex if you want. I’ve done it before when I’ve lost a few. No catastrophic issues arise.

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Only diesels in this driveway.
2005 E320 CDI 243k Black/Black
2008 Chevy 3500HD Duramax 340k
2004 Chevy 2500HD Duramax 220k

Well, I couldn't help myself, I like older tools and saw this Cornwell Cat 250 air drill for $34, had to buy it. I should be better off with this than the Husky air drill.

https://www.ebay.com/itm/3-8-REVERSIBLE-AIR-DRILL-AIR-COMPRESSOR-DRILLING-TOOLS-/350374540511?oid=183563327249

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Left hand drill bits didn't do jack ****, extractor broke off in the head.

I'm contemplating selling the car, I can't go any further. I'm out of options, I refuse to do anymore drilling.

And NO the extractor isn't cocked.

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Can I just drive to a machine shop and let them work on it?

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Around these parts machine shop labor rate is between $100-150 an hour, and usually no guarantee as to what they can accomplish without getting into the challenge or at least a thorough look at what's going to be involved.

Any chance you can post some pictures of the actual situation, that might help figuring out what the available technique might help.

Why don't you just weld a nut to the flush broken stud? The heat from welding frees up the remaining section.

Has worked 100% of the time for me, even on old exhaust manifold studs.

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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

Long-shot idea here but can you put the manifold back on and tighten it down? If so the bolthole for broken one might make a nice sleeve to drill out what's left of the bolt in the head. Just a thought. If it works I guess you could helicoil it and move forward.

I don't know how to weld nor do I know anyone with a welder.

So I acquired some diamond embedded grinding burs, i plan on grinding the extractor away. Will penetrating oil help with grinding away the metal the same way penetrent helps with drills?
I never got the intake manifold off.

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Pics of the situation that can't get any worse. Like I said, it's a size to big so it's flush in there.

Attached Thumbnails

     

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Are you sure the SOV is cracked? I read on these forums where someone thought their SOV was cracked but it was the o-rings inside at each end. The thread had detailed instructions and pictures on how to replaced them, if that’s your problem?

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1998 E300 Turbo Diesel, 221k Miles
2018 Chevrolet Colorado Z71 4X4, V6, 19k Miles
2007 Honda CRV, 115k Miles
2011 Kawasaki Trans Mule, 212 hrs, (grandkid hauler)

I just noticed the pictures you posted of the broken bolt. It looks like once the intake manifold is removed, there might be enough bolt left to put a pair of vise grips on. If you can, work it back and forth some and see if it’ll come on out.

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1998 E300 Turbo Diesel, 221k Miles
2018 Chevrolet Colorado Z71 4X4, V6, 19k Miles
2007 Honda CRV, 115k Miles
2011 Kawasaki Trans Mule, 212 hrs, (grandkid hauler)

It is the intake manifold. It is under vacuum, not pressure. Take the manifold off. Do what you need to do and put the manifold back on. Drive the car. You don't need all the bolts. Don't over tighten. The threads are in aluminum and strip easy.

My '96 E300D, by the time it had 300k+miles, had at least 2 intake bolt holes that were stripped and barely held the bolts in place and applied almost no pressure to securing the manifold to the head. If it makes you feel better us a gasket sealant of some sort, but I wouldn't bother.

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Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

Sounds good to me.

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CC: NSA

All things are burning, know this and be released.

82 Benz 240 D, Kuan Yin
12 Ford Escape 4wd

You're four times

It's hard to

more likely to

concentrate on

have an accident

two things

when you're on

at the same time.

a cell phone.

www.kiva.org It's not like there's anything wrong with feeling good, is there?

I got all the bolts out but it still won't come off. I ended up grinding down the extractor, then I just drilled straight through.

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

I can rock it up ane down but can't pull out.

Attached Thumbnails

 

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.