I was finishing replacing the pre-filter on my 1996 E300D, trying to fix a air/fuel leak problem of the o-ring, and as I attempted what I thought was normal tightening of the screw that secures the pre-filter and incoming fuel line.....the screw head and half of the screw popped right off........uh-oh........

What do I do now......

I am sure you guys wives could do a better job of simple maintenance than this. Do I have to procure a new fuel filter housing (one without a broken screw therein) and screw, of course?

Idiot question, but I presume she is undrivable right now, as there is nothing to secure the filter in place or the incoming fuel line to the pre-filter.

Thanks,

Embarrassed Idiot

One of the cardinal rules in working on cars is to never force anything, although it sounds like you didn't really force anything. Get the factory service manual for your car. It will have all the torque specifications.

Yes the car is undriveable if the fuel system is not sealed.

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Doug

1987 300TD x 3
2005 E320CDI

Okay, I have regained what little sense I have, I think.

How about a screw extractor...drill a hole in the broken screw, use the extractor to back her out. Buy a new screw (special at all, or can I find the same threading on a screw at a hardware store?) put it in a little more carefully, and I'm back on the road....

You have to be careful to drill right in the center of the bolt so you don't get into the threads. The conical screw extractors work OK, but the straight ones that get driven in work much better. They also come with the correct drill bits in the extractor set.

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Doug

1987 300TD x 3
2005 E320CDI

The use of a center/spot drill before the regular drill is a must.

I've had great luck with standered ez-outs. The key is to use the biggest drill bit you can for the size of the ez-out, so your more towards the shank of the ezout. I recomend a Tap Wrench for use with an ez-out (the ones with the drill style chuck, not the "box" kind)


I've had to mill a 5/8 - 11N.C. SHCS out before. THAT was no fun.

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)

Well, problem solved for now. I was unsuccessful at getting a good hole through the center of the screw, as when it broke off, the remaining piece inside the fuel filter housing is thick and protrudes out towards me right in the middle of the screw. I had to drill out the entire screw and re-thread the opening. Seemed to work fine, though if I had one size larger tool I could have bored and re-threaded an even sturdier new threading. Its holding just fine though.

Anyone think in the long run I should pony up for a new fuel filter housing?