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Thread: Broken Bolt

  1. 4th February 2008, 08:22 AM #1
    Cool95
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    Broken Bolt

    Yesterday I decided to remove and replace the manifold gasket which had blown. After treating all bolts with penetrene for a week surprising the exhaust manifold bolts came off easily, but one of the inlet manifold bolts wouldn't move, it slides in a sleeve in the manifold so getting the penetrene to the thread was extremely difficult it was very tight considering the other one didn't require much pressure.

    Anyway the bolt snapped leaving about two thread lengths sticking out of the block. It was late so could not get any easy outs, has anyone got an idea of a jig to keep the drill centred and straight on a horzontal surface, without the turbo pipes access is very easy.

    One other question the bolt has had water on it over time which could account for the break, the head of the bolts are corroded can't tell if it is high tensile or not some help here would be appreciated.
    http://www.aulro.com/afvb/images/smilies/sad.gif

    Thanks in advance
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  2. 4th February 2008, 08:37 AM #2
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    dhard
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    Bolt will be high tensile when you say it had water on it where was it coming from?
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  3. 4th February 2008, 09:09 AM #3
    Cool95
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    Since I have had the truck about 6 years there have not been any water leaks in this area can only assume it happened before I got it it's a 95 tdi...
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  4. 4th February 2008, 09:59 AM #4
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    I just did mine the the other day inlets stripped on me so i just got away with putting two helicoils in. It still leaked afterwards so ended up putting some high temp gasket goo on the back of the gasket and now it's dry as a bone. Still strange for water to get in those bolts must hve come from top pipe that runs along the intake.
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  5. 4th February 2008, 10:55 AM #5
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    CraigE
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    If you can get some multi grips on what is left and maybe some loctite freeze spray it may help.
    Cheers
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  6. 5th February 2008, 09:17 AM #6
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    camel_landy
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    A clout with a centre punch & hammer into the top of the bolt not only will help locate the drill bit but it might also help release the threads...

    HTH

    M
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  7. 5th February 2008, 11:21 AM #7
    Phillip
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    The best penetrating fluid for siezed bolts is Rocol RTD Metalcutting Fluid. I have used it for years when pulling down old tractors. Just apply and leave for a couple of days and the bolt will easily come undone.
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  8. 5th February 2008, 11:24 AM #8
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    rocol it is dam fine stuff..... only 1 thing better but it costs 10 times as much :P
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  9. 5th February 2008, 04:34 PM #9
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    before you start goto a top notch tool store and buy a left twist drill I have a set and 90% of the time they will pull the bolt out before I even get to the easy out.
    Dave

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  10. 6th February 2008, 09:20 AM #10
    Cool95
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    Thanks for the advice will give it a few days soak with penetrating fluid, then drill a hole, spray it with locktite freeze and use an easy out should work ok....

    As a last resort a dremel with a diamond tip can literally rip through it although a tap might be needed afterwards, a work collegue did this to remove not only a broken bolt but also the broken high strength easy out as well !
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