603 engine coolent neck leak
 

This coolent neck gasket was leaking a bit on the aluminum head of the 87 124 603 engine, diesel, the bolt broke. While drilling out the bolt, the drill bit broke off inside the bolt and is firmly buried inside it. Now I can't get anything done here.

I've extracted a few broken bolts in my life but this one is just cursed.
I am open to suggestions. Help me Obi-wan.

Here in los angeles, we use a company that will electrically remove exactly whats happened to your block, its not cheep, they now will drive a van to you to remove the broken drill bit with 100% success , ill get you the number Monday as im not at work

I am sure a professional with a "super" hard drill bit can drill a hole and extract the broken bolt out.

This is the cheap man solution but use it as a last resort. It happened to me with the exhaust stud on the om603 block. The stud broke and ditto the drill bit. I used this method and it worked but use it at your own risk. I used acid to dissolve the broken drill bit. I dripped acid into the hole, a few drops a day and the acid dissolved the iron. See whether the bit is loose after a few days and then try to wiggle the broken bit out. The acid may also dissolve the aluminum, it shouldn't but it did. So you may need to retap the hole afterwards. Good luck.

Nulu, I am not familiar with this process, but it is probably worth doing even though this is a #14 head - it doesn't leak, mix coolant and oil or any of that stuff. I'm going to quit fiddling with it for now.

I searched online and found someone in LA called the bolt guy. boltguy.com I've contacted them. I just don't see this service from anyone in LV. But I'm going to check around before towing her to LA.

Found this guy, The Bolt guy 951 264 9177 in Moreno valley,
www.boltguy.com/‎

mailto:boltguy@gmail.com

Curious as to what type of acid you used hoping to dissolve the iron drill bit without also expecting the acid to attack the aluminum head.

Hydrochloric acid will dissolve iron. If you want to take a long view then water will do the same :). I used pool acid and it was a success. It took some aluminum off but it was because I left the acid in there for too long. It is definitely doable as I did it successfully. As I have said, it is the last resort.

When this happens, I use a small drill to remove material around the broken drill's flutes. Then a small needle nose plier to twist the stub out. Usually spoils my day.

Of course hydrochloric acid will dissolve iron, and it will also dissolve aluminum (violently) once it has penetrated the outer layer of aluminum oxide. Your success (to use your term) came from the degradation of the aluminum which loosened the fit between it and the drill bit. New tapping for a larger bolt is strongly recommended.

that blows....
keeps us updated and best of luck

Given that this bolt is fairly accessible - the only good part of this problem - i'd like to find a removal shop here in Las Vegas. There are a couple listed in LA - anyone know of a good electric/removal shop in NV?

DIY EDM?
 

That's a cool video. I got hold of Eric's Laz R Out Eric's Laz-R-Out: HOME near L.A. and I'm going to tow ol' 87 down to Barstow next week and we'll meet and he'll do the extraction. Nobody here in Vegas is available apparently. I'll report the experience back here. Eric told me he gets calls from all over the country. He travels quite a bit in so. cal. Nice guy.

Took ol' 87 down to Barstow on a dolly (rear wheels up) and met Eric, mentioned above. He drilled that bolt out expertly and when it was determined that the threads were not so great, he drilled it out and tapped it and installed a helicoil perfectly. Eric is fastidious on the angle of the drill so that the new hole is perpendicular to the surface. Frankly, this was a costly mistake on my part. Should have nursed that bolt out with more patience. Anyway, the coolent neck is back on and not leaking. Now I'm on to the next project on this 124.