fuzzychi

iTrader: (3)

I was removing the two downpipe bolts yesterday with my breaker bar when one of the bolts sheared off and broke during removal. Basically all I see now is the threaded portion stuck inside the hole on the hotside. I was thinking of using a bolt extractor but not sure if it will break as well since the bolt seems really tight in there right now, seeing as it broke the previous bolt.

Any ideas or suggestions will be greatly appreciated, thanks!

nemsin

iTrader: (19)

Probably have to drill it out.

Bobster22388

iTrader: (13)

Spray it with some PB blaster and let it sit. Do that a couple times, then you might have to hit it with a torch and get it nice and hot, then let it cool (expands, then contracts which may get it unseized), drilling it out in that location without taking the turbo off will not be fun at all.

fuzzychi

iTrader: (3)

After PB Blaster and torching it do you think the bolt extractor would be strong enough to remove the remainder of the bolt?

syclone50

^^^^I had this happen to me too. Use the PB Blaster and let it sit. Drill it out and hit it hard with a torch, then use an easy out.
You may want to also try drilling it out with a reverse drill bit. It may bite hard enough to back it out

Good luck

fuzzychi

iTrader: (3)

Sweet, gives me some hope then I'll give that a shot, thanks man!

Bobster22388

iTrader: (13)

Bolt extractor is definitely strong enough to do the job, just make sure you drill the hole the right depth and size according to the EZ-out your using.

syclone50

OP did you ever get this thing out

DarksideZ

iTrader: (1)

I hate it when that happens.

fuzzychi

iTrader: (3)

Yea couldn't get it out the bolt extractor broke right off when I was torquing it to remove the bolt. I'll need to remove the o2 housing and try to get the rest of the bolt out or just replace the o2 housing.

fueler11

My IX had one bolt that was very resistent to turning, it was tight all the way out, the other side was fine. I wondered if anybody else might have a problem. Mine didn't break off but I'm going to take the down pipe off again and fix this before it siezes in place.

Anyway, if you have a welder, put a nut up there on that stud. If what's left is flush with the base of the 02 housing then weld that nut to the stud. Then you can use a socket to remove it. Just stick your welder throught the center of the nut and weld it on. Good luck.

Evoryder

iTrader: (55)

Double nut and remove if you got enough thread. Pb blaster overnight, hit it with a torch till the bolt is glowing. The remove.

For the future anti seize on pretty much all high torque bolts eg hotside, manifolds, down pipe etc

2d-ink

iTrader: (3)

Had the same thing happen. brought it to a Machine shop they told me $60 to remove it. I just junked it and bought a Megan O2 elbow