SNAP! Exhaust bolt

[TurboAddict]

Was going to change my chaincase oil and started removing the exhaust bolts... You know what happened. Only one though.

So my question, any tips on extracting the stud to replace? Or anybody see an issue with leaving it, and running just the 5 bolts?

 

[KnappAttack]

Weld a nut on it and remove it when the heat dissipates into the housing just a bit.

 

[TurboAddict]

Unfortunately I have to welding experience... Do you see an issue with me leaving it as is? I am nervous to try drilling it

 

[no1b4me]

Unfortunately I have to welding experience... Do you see an issue with me leaving it as is? I am nervous to try drilling it

Can you post a picture of the broken bolt in the turbine housing ? This way the best advice can be given on your next steps.

 

[Pstn head]

There shouldn't be any issue with running 5 bolts if the one in the centre is the broken one (keep an eye for equast leak though) Like knapattack said have someone weld a bolt then try removing it. Or drill and reverse tap it out. When installing the bolts apply some copper or nickel antisieze and torque properly. When removing at next service a little heat will help removal of the bolts, run engine up to normal temperature then remove the bolts.

 

[yamamarc]

Best to deal with it now!!!imo
Weĺd a nut like Knapp mentioned
Or grind broken end of bolt flat then center punch the center of broken bolt.
Start with a 1/8" drill bit then then 1/4" ......
Once you have a big enough hole in bolt you can try a easy out. Heat housing before attempting to remove with easy out.
If not luck continue to drill hole bigger and try again.
Once you get close the the root of the threads it should break loose with a easyout.
Make at peice of plate with holes to match muffler flange and bolt it to turbo to protect and keep shaving out of turbine

 

[STAIN]

Why did it break? was it seized or was the bolt fatigued? If it was not seized and the bolt was just fatigued try drilling it out with a left handed drill bit. Sometimes the bit will catch the broken bolt and spin it out.
Drilling it out isn't a bad job. Just make sure it is center punched and cover the turbo with tape. Like yamamarc said, start with small bit and get progressively bigger.

 

[TurboAddict]

Here's some pictures. It broke while removing to change chaincase oil. I stopped at that one. The 3 on the right side came out fairly easy. After that one broke I got nervous to touch the 2 that require the ball end torx or a "custom" cut torx.

 

[KnappAttack]

Thats an important bolt you'll need IMO. You will have to get a friend to weld a nut on it. Start the machine to warm the turbine housing to remove the remaining bolts!

 

[sideshowBob]

I agree with Mike and would not let that go except for limited use. You could run sled to load on trailer ect or to take to someone like a machine or welding shop. They easily would repair your issue.

 

[TurboAddict]

Ok, so assuming I can get the other 2 out... I should first attempt to have someone weld a nut onto the remaining stub of the bolt? Use the drilling and extractor method as back up?

 

[1nc 2000]

Take a hammer and large punch and hit each bolt 3-4 times before breaking loose. It helps crack the threads loose. Then remove bolts.
Looks like enough bolt there to weld on once muffler is off.

 

[KnappAttack]

Ok, so assuming I can get the other 2 out... I should first attempt to have someone weld a nut onto the remaining stub of the bolt? Use the drilling and extractor method as back up?

Remove the muffler first, then use a wire feed and weld a nut on to remove, it will come right out when you get a good & hot weld on it. The nut can be slightly larger than the broken bolt, does not need to be the same threads as the bolt or nothing. Get it to a friend that maybe has done this before with a wire feed.

The other bolts will come off after the turbo is warm from being run a bit.

 

[TurboAddict]

Remove the muffler first, then use a wire feed and weld a nut on to remove, it will come right out when you get a good & hot weld on it. The nut can be slightly larger than the broken bolt, does not need to be the same threads as the bolt or nothing. Get it to a friend that maybe has done this before with a wire feed.

The other bolts will come off after the turbo is warm from being run a bit.

Thanks for all the help. Reached out to a buddy be with a welder, going to give it a shot this week.

 

[TurboAddict]

Good news so far, warmed the sled up and used the cut torx to remove the remaining 2 bolts. At least I can continue my chaincase oil service, and chain tension.