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Sheared bolt head off OM606 intake manifold, now what?
I soaked all of the bolts in Phosphoric acid to remove rust, I cleaned the the inside of the nuts, applied valve lapping compound to t40 torx bit for more bite, and applied penetrating fluid multiple times.
Unfortunately the VERY LAST nut got stripped, then I got bolt extractor (the socket NOT drill bit) and the nut began turns then it sheared off. How am I supposed to get the stud out the head, am I simply royally screwed?
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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. |
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1997 E300 Diesel - 222K miles |
#3
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Easy out! They should have came out without any of that prevantitive work. You need the hammer the T40 in there before you try and turn it or you’ll just strip it like in your case. They get dirty inside there and you’ll think the socket grabbed and it won’t.
You should just get an easy out though. It won’t damage the threads.
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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 |
#4
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https://www.lowes.com/pd/IRWIN-Hanson-10-Piece-Spiral-Screw-Extractor-and-Drill-Bit-Combo-Pack/1000363539 I'm going to have to buy a drill too, a ceter punch and maybe a T handle right? Also what fastener can I replace it with, can I buy a generic hex bolt at lowes/homes depot or will I have to go to McMaster-Carr?
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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. |
#5
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Beware the spiral EZouts. They usually wedge in and tighten the broken bolt even worse thsn it is. See if you can find a square EZout. They work 1000 times better.
Another thing worth having in any shop is a set of left hand drills. You can often get the broken bolt out just with the left hand drill, before even resorting to the EZouts. Trick is to step drill, starting with a very small one. If that one doesn't back it out when it breaks through the bottom, go up one size and try again. Spray some WD-40, Kroil, or other penetrating oil in the hole now, too. If that one doesn't grab and back it out, then repeat until you are about 60% or so the diameter of the bolt and then use the EZout. BTW, I am a machinist at a pump shop and remove broken bolts almost daily from cast iron, stainless. bronze and aluminum parts. |
#6
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Also can I patch my SOV for a temporary fix? I'm sure my SOV is cracked.
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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. |
#7
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Why an air drill? Not a battery operated? Get a Makita 12v. Also take one of the bolts to the hardware store and find the same size. I got my intake manifold bolts from Home Depot but I know Lowe’s has ones that work.
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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 |
#8
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You know what, I'll put everything back together and buy it next paycheck. No need to bleed out.
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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. |
#9
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I must be missing something, nuts and bolts on a 606 manifold? If you sheared the head off the bolt why couldn't you pull the manifold and then use vicegrips on the threaded shaft left behind. If there's still some 'head' left on the bolt can you drill/cut it off and then pull the Manifold?
You can swap out the SOV leaving the manifold in place by moving the washer bottle out the way. Not as roomy as with the manifold out, but can be done. Please be careful of the torx bolts on the SOV....I stripped one of them over a year ago, which has delayed my SOV replacement for a long while. It was a PITA to get that bolt out of the SOV. I finally figured out to drill the head slightly larger/deeper than the speed out's diameter I bought from the Orange Box. Clean the torx bolts with brushes and brake cleaner so you get a great grip on it with the T27. Those bolts are not made of very strong metal and who knows how badly they maybe over torqued from prior service.
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Treetops 06 E320 CDI 127K Miles 87 300TD 231K Miles 99 E300 269K Miles-Sold |
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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. |
#11
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There is the bolt underneath the manifold that fixes the EGR tube to a support, If that's not off, then no the manifold wont move. You can only get that one from underneath the car with about 18" of 1/4' drive socket extensions. Ive, umm, lost mine somewhere along the way.
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Treetops 06 E320 CDI 127K Miles 87 300TD 231K Miles 99 E300 269K Miles-Sold |
#12
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Ok know wonder it wouldn't come off.
Off to harbor freight for MORE extensions
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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. |
#13
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One six extension and a wobble and 3/8 does the trick. Easy to do.
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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 |
#14
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Also Jake, should I use anti sieze on the bolt threads and is it possible to convert from torx to hex bolts?
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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. |
#15
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