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AAAAAAAAARGGHHH intake bolt BROKE OFF


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16 replies to this topic

#1 baccaruda66

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Posted 17 August 2003 - 12:01 PM

************************************************
EDIT
there's a crapload of metal shavings in the intake port from the hacksawing... I can flush out the coolant port easily with a hose before the new water pump goes on, but i'm worried about all the metal shavings in the intake port.
should i even bother to try cleaning it out, or am i just asking for a bunch of valve problems if i try to clean it and run it? I can eat the money i paid Bob for this engine and get another one if i have to.

thanks very much to all.
*******************************************



I had a head snap off of an intake bolt. used PBBlaster and lots of patience on all of them, and of course it had to be the last one, and it had to be on the long block I want to use instead of the disposable one.. it snapped off right away at the head of the bolt, though, so i don't think it really had a chance. whoever designed those to go through cooling passages should have an engine block thrown at their head..

I have some wiggle with the intake but I'm worried about damaging the threads in the head as the bolt in the intake isn't turning, rather, the whole intake is turning along the threads in the head.

anyway, i'm considering a few things:

hacksaw through the intake (aluminum is soft!) next to the bolt, then the intake will easily slide off?

or..

screw extractor into the bolt.. i'm not to enthusiastic about this though.. see the "wiggle" paragraph above. I'd be open to doing this after the hacksaw thing though.

Also, will I want to helicoil the head if the threads look whacky?

thanks..
Andy 509-263-3853 .. i can carry the phone outside but not the puter ;)
oh, and i don't have a torch so applying heat will have to be limited to pouring lighter fluid on it and tossing a match.. not my first preference :D

#2 TheSubaruJunkie

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Posted 17 August 2003 - 12:06 PM

Well... if the head snapped off the bolt, that means theres probably a good 2" of bolt exposed from the head. Try to remove the intake, might need to file the end of the bolt alittle to get the intake to slide off... but shouldnt be too difficult.

I would either:
Try to extract the bolt by using some vice grips on the exposed part of the broken bolt.

Or maybe drill a hole through the bolt, through the side of the bolt... try to find a punch or something that will fit through that hole and use that to turn the bolt out. Might want to heat up the head with a torch. That should make the head expand and make it easier to retrieve the bolt.

Since you have a fair amount of bolt exposed, it shouldn't be hard at all, and if your careful you should be able to save the head, intake and replace that broken bolt.

Also.... make sure you put some rags or something into the intake on the head so metal shavings dont get into your engine.

-Brian

#3 TheSubaruJunkie

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Posted 17 August 2003 - 12:09 PM

Woops... just re-read something:

I have some wiggle with the intake but I'm worried about damaging the threads in the head as the bolt in the intake isn't turning,
rather, the whole intake is turning along the threads in the head.



Does that mean when you rotate the inatake manifold, the bolt is actually rotating with it? If that is the case, you might be able to rotate the intake until the bolt is removed from the head all together. There should be no threads threaded into the intake manifold, so if you get the intake off and the bolt is stuck to the intake, you could tap it out with a hammer.

-Brian

#4 canajun2eh

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Posted 17 August 2003 - 12:20 PM

Helicoiling shouldn't be necessary after you've extracted the broken bolt.

As with the cylinder head bolts, you should carefully CLEAN the bolt threads as well as the tapped holes in the cylinder head before reinstalling the intake manifold. Don't forget to oil the bolt threads. Obviously, you also have to clean the holes in the manifold that these bolts go through.

#5 baccaruda66

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Posted 17 August 2003 - 04:34 PM

hi guys. thanks for the replies.
the head and top 3 mm of the bolt shaft are what snapped off. i can't unscrew the whole intake as the bellhousing is in the way.
I spent ALL DAY so far dealing with this and haven't even gotten my hands dirty yet :banghead: .. YESTERDAY I spent 5 hours tracking some bandwidth hijacker that prevented me from using my internet last night (note to self: Norton Personal Firewall only works when it's INSTALLED on the computer, not SITTING onthe computer waiting for said installation) .. this AM, didn't get up too late (my usual mistake :P ) but i went to Mom's to grab some extra bolts from my planned XT intake swap, had to help my brother cart a shelf and a dresser outside as he's moving, and hit the hardware store across the arterial.. they didn't have the right size screw extractor.. i went PAST Lowe's, because they suck, to Home Despot, looked around, and because I hadn't eaten yet, decided for some reason that it would be better to go back to Lowe's.. got the extractor and a hacksaw and NEEDED to eat by this point.. and you know how it is when you're too hungry.. nothing sounds good.. except Burritos! I had to arrive there (on the way home at least) to find that they're closed Sunday. On the way home I had to power brake to avoid a car full of stupid old ladies who ran a yield sign, when I was on their right, no less (note to self: quit driving when I'm too old to drive), and the crap in the back of my car went everywhere..
SNAP.
got home, slammed the car doors, slammed them again for good measure, went in, and passed out for a half hour.

So I went back out, ate a bagel and the girl at the Rocket bakery was all flirty, and I'm going to go teach that bolt a lesson.

THE MORAL OF THE STORY:
Breakfast is the most important meal of the day. And install a freakin firewall.

#6 TheSubaruJunkie

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Posted 17 August 2003 - 04:45 PM

If you dont need that intake, cut it in half :)

Like i said, that bolt shouldnt be attatched to the intake like that. its probably rusted in place.... you could probably break it loose somehow. Pry that bad boy off the head (the intake, not the bolt).

If you can get the intake to come part way off, unscrew it alittle maybe so there is some space between the head and the intake. Smack the intake with a hammer and it might break that bolt loose from the intake and let it slide off.

-Brian

#7 beauregaardhooligan

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Posted 17 August 2003 - 05:09 PM

My Dad showed my a neat trick with an allen wrench. Drill a hole in the top of the bolt and tap an appropriate size allen wrench in. If your lucky it may come right out.
There are also cam-style stud extractor/installers that work very well with a rachet. NAPA has them.

#8 oobnuker

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Posted 17 August 2003 - 06:23 PM

I had the same thing happen on my parts car - EA82T. Bolt snapped about 1/4" below the surface of the intake.

The key to the success of this one was to pretend that I didn't want or need the motor...:mad:

I ended up using like a 30" prybar - trying to find the meatiest pieces of aluminum to lever against - avoiding any mating surfaces, etc. I beat on it with a 2lb mallet too. Finally started to get movement, and it finally slid out. No damage to anything. The bolt turned out EASILY with vicegrips once the intake was off.

#9 TheSubaruJunkie

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Posted 17 August 2003 - 06:29 PM

That was an idea i had but i didnt want to advise you to pry on aluminum... just beat it with a hammer.

-Brian

#10 oobnuker

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Posted 17 August 2003 - 06:35 PM

I guess it's one of those things that everyone does at some point but might not ever suggest anyone else do it...

:lol: :lol:

#11 gravelRX

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Posted 17 August 2003 - 08:15 PM

I took the intake off my RX and got Very lucky that none of them broke.

I see a couple problems you probably already figured out.

To get the intake manifold off your going to have to tilt it backward to clear the ancillaries on the front of the engine. Then when you get it high enough you're going to have to tilt it back to clear the bellhousing. Big PITA even without breaking a bolt.

Find a nice sharp punch and see if you can get a good solid whack or two onto the broken bolt shaft. I mean, smack it good.
Make sure your punch is dead center in whats left of the bolt.
This is to loosen the deathgrip of the rust on the bolt and corrosion on the aluminum.

Next, and I'm sure you have done this, coat it in PB blaster or the like.
Now, while it's soaking, go to Wallyworld and spend twenty dollars on a propane, or better, a MAPP torch(hotter.) Go ahead, you will use it again. Even if it's to start the grill for chicken, you got to eat.

Take a few deep breaths and with lots of water to put out a fire, heat the intake around the bolt. No, more. Until your elbows and back hurt from staying in that position. Quench the hot aluminum with a splash of water and pull, tug, pry(gently), on the intake to get it loose from the bolt. no? Do it again.

Hopefully you will be able to get the intake up from the bolt far enough to start the acrobatics to get it out.

Good Luck. Remember to walk away when you bust your knuckle or become frustrated. Good practice for when you have kids.
Regards,
Jay

#12 baccaruda66

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Posted 17 August 2003 - 10:09 PM

well. it's off.
lots of hacksawing involved. screw extractor was worthless.
ended up sawing the intake off leaving the water neck and of course the part bolted to the head.
i didn't mention that i pounded the hell out of it the other day, so i didn't bother with any more of that today. finally got sick of hacksawing and drilling and grabbed the new prybar set i grabbed at sears yesterday; didn't do TOO much prying with them yesterday but i just decided "screw it" and it took a lot, but it finally popped off. oh, yeah, this was after i sawed laterally thru the intake and the bolt halfway, too, so it had less of itself to grab. the stud came out easily.. no surprise there between a half can of PBBlaster and all the wiggling I did. I expect the threads will be OK (bought a 1.25 tap today to chase all 6 of them) but ....

there's a crapload of metal shavings in the intake port from the hacksawing... I can flush out the coolant port easily with a hose before the new water pump goes on, but i'm worried about all the metal shavings in the intake port.
should i even bother to try cleaning it out, or am i just asking for a bunch of valve problems if i try to clean it and run it? I can eat the money i paid Bob for this engine and get another one if i have to.

thanks very much to all.

#13 TheSubaruJunkie

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Posted 17 August 2003 - 10:21 PM

Well aluminum shavings cannot be good for your engine. Might wanna get one of those cool vacuum atatchments for keyboards, and suck as much of that as you can.

-Brian

#14 XSNRG

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Posted 17 August 2003 - 11:24 PM

Edit

#15 skeet

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Posted 18 August 2003 - 12:49 AM

Dude, just rotate the engine so the intake is facing the ground, pick it up, and shake it real good.

Wuss.

#16 baccaruda66

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Posted 18 August 2003 - 03:39 AM

my kung fu grip is a little .. not there.
i'm going to jack my dad's air compressor and get a small inspection mirror.. best i can do. if nothing else i'll buy you the FIRST engine :)

#17 canajun2eh

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Posted 18 August 2003 - 06:45 AM

I'd advise removing the cylinder heads, removing the valves, and using lots of compressed air to blow those shavings out.

You can use water to flush out the intake ports too.




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