EGR Removal Broken Bolts

[sigurross]

HELP!

I was removing the nuts to get the bottom of the egr out and bolts broke! To be honest I wasn't even applying that much torque. Any suggestions as to what I should do here I'm completely at a loss?



What is the worst case scenario if I can't get this fixed, new exhaust manifold?

- Jason

[nxski]

Drill it out. You shouldn't have to replace the manifold.

[dennis_lambert]

You have a couple of possible options....
If there is any stud left sticking out sometimes you can get lucky by using vise grips and heat.....
Or I recomend soaking in aerokoil then use a center punch to mark center of hole use a angle drill with a 1/8 bit and drill a hole in center of stud then smack a 1/8 snap on easy out finally heat up with small propane torch (Carefull Aerokroil is flammable!!)and attempt to back out the stud.
In failing that...keep up sizing the 1/8 hole until there is nothing left of the stud and then Re-Tap to the next stud size up.
Good Luck!

[legionnair]

Another option is to grind flush then center punch and drill a new hole, tap it and build your block off plate to suit.

[sigurross]

Thanks all for your responses. You've given me lots to try.

I suspect most of these methods (aside from the vice grips & heat) will involve removing the manifold?

- Jason

[dennis_lambert]

Another option is to grind flush then center punch and drill a new hole, tap it and build your block off plate to suit.

Good Idea...
Sigurross if you are going to drill a new tapped hole and require an EGR blank blanking plate (No holes) I have quite a few slightly Mis-shapped ones I could send you.There made out of 1/4 steel.
Cheers!

[vixentd]

SLIDE a slight bigger nut on and mig weld the nut to the stud. Then use a socket to remove. The heat will break any bond with the manifold. No removal of manifold needed.

[dennis_lambert]

Thanks all for your responses. You've given me lots to try.

I suspect most of these methods (aside from the vice grips & heat) will involve removing the manifold?

- Jason

Actually there is quite a bit of room...with removing a few parts..
-First remove Seat
-Remove air filter housing/Glow relays access panel..
-Then Remove dozen or so bolts retaining Access cover(Don't bother Disconnecting E-brake or Gas fill leaver)Push aside,next remove ducting and voila plenty of room to contort your hands and bash your knuckles...

[sigurross]

Anybody in the Victoria area willing to help me out with this today? I will reward with as much beer as you want!

- Jason

[RichD]

Jason,

Well you haven't called me yet so here is the deal.

This has happened to me too on old motorcycles. Those fasteners tend to rust up and come out, although this is the first one I've heard of breaking off. I've started including extra fasteners with the kits for this reason.

So what you are going to have to do is, as many of the posts say, extract or drill out that fastener and probably replace the threads. If you can remove the manifold completely it will be much easier to do properly.

I am willing to gather up the necessary tools and come out to Victoria to help. Get in touch with me (not here).

-Rich

[sigurross]

Richard, sorry didn't call, thought i'd take a crack at getting it out before I wasted your time. I torched it for a bit and then pryed on it with some vice grips and after much persistance I got it out!

I ended up pouching some bolts from the egr itself and using those to secure the blanking plate to the manifold. I rev'd it pretty hard and no exhaust was leaking and my pryo was getting a good reading.

All is good for now. Thanks all.

- Jason

[legionnair]

Remember to put some never seize on the bolts just in case you want to remove them later.

Dustin

[RichD]

So glad to hear of your success!