My car is cursed (aka a 2 hours job becomes a 2 day job)
Mar 6, 2009, 08:06 AM
#1
My car is cursed (aka a 2 hours job becomes a 2 day job)
So my saga begins here: https://www.evolutionm.net/forums/ev...ce-skills.html
Cliffs Notes: UR o2 housing/downpipe cracks a weld, UR steps up and gets me a new one quickly
Fast forward to yesterday. I get in the new part. Swell, let's go put it on.
The third bolt I get to is seized up! I've had the o2 pipe off once before in January, so I don't know what the heck is going on. So I hit it with some liquid wrench and get one other bolt out to give it some time.
CRACK. Bolt snaps in half. This is the second o2 housing bolt that I've heard of cracking when being removed.
fugity fug fug fug. Now the hotside has to come out in order to get the bolt out.
Getting the hotside off on the X is a bit of a PITA.
1. Remove the UICP
2. Remove the intake
3. Removed the nuts on the exhaust manifold (try not to lose the washers -- but they should be replaced anyway)
4. Remove the nuts on the outer studs on the hot side
All fine and dandy to this point! Good. Here's where the story gets "fun"
5. Remove the bolts holding the hot side to the manifold
or if you're like me these f'ers are seized too. Proceed to ruin three socket heads (make quick trip to lowes for a new 14mm 1/2" socket) while completely stripping the threads off the bolts clean. Hopefully the hot side threads are ok and just need a clean/retap (or else its helicoil time). One of these bolts had previously worked it's way completely out (and this was a week ago)! I have no idea how come it was completely and utterly seized!
6. remove the bracket on the drivers side of the turbo
7. remove the shield on the xfer case
8. remove the buried 14mm bolt that is in the worst possible place ever since you can't get a freaking socket or wrench on it.
9. Give up on the bolt until the morning, spraying a bit more lube on it.
10. Get up early since you can't sleep and in 5 minutes take the bolt that you worked an hour on the night before out.
11. push the turbo back (it's loose now) and pull the manifold off
12. undo the clamp holding the turbo together
13. carefully slip the hotside off
I forgot to profit somewhere in there!
Sumna*****. Now I need to get the bolt extracted from the hot side, get two bolt holes cleaned/retapped and those studs on the top of the hotside? They have to go! I think I understand why they are there, but fer cryin' out loud, the job would have been way easier if the manifold was hooked to the hotside with bolts and nuts.
So how'd you spend your Thursday night?
Cliffs Notes: UR o2 housing/downpipe cracks a weld, UR steps up and gets me a new one quickly
Fast forward to yesterday. I get in the new part. Swell, let's go put it on.
The third bolt I get to is seized up! I've had the o2 pipe off once before in January, so I don't know what the heck is going on. So I hit it with some liquid wrench and get one other bolt out to give it some time.
CRACK. Bolt snaps in half. This is the second o2 housing bolt that I've heard of cracking when being removed.
fugity fug fug fug. Now the hotside has to come out in order to get the bolt out.
Getting the hotside off on the X is a bit of a PITA.
1. Remove the UICP
2. Remove the intake
3. Removed the nuts on the exhaust manifold (try not to lose the washers -- but they should be replaced anyway)
4. Remove the nuts on the outer studs on the hot side
All fine and dandy to this point! Good. Here's where the story gets "fun"
5. Remove the bolts holding the hot side to the manifold
or if you're like me these f'ers are seized too. Proceed to ruin three socket heads (make quick trip to lowes for a new 14mm 1/2" socket) while completely stripping the threads off the bolts clean. Hopefully the hot side threads are ok and just need a clean/retap (or else its helicoil time). One of these bolts had previously worked it's way completely out (and this was a week ago)! I have no idea how come it was completely and utterly seized!
6. remove the bracket on the drivers side of the turbo
7. remove the shield on the xfer case
8. remove the buried 14mm bolt that is in the worst possible place ever since you can't get a freaking socket or wrench on it.
9. Give up on the bolt until the morning, spraying a bit more lube on it.
10. Get up early since you can't sleep and in 5 minutes take the bolt that you worked an hour on the night before out.
11. push the turbo back (it's loose now) and pull the manifold off
12. undo the clamp holding the turbo together
13. carefully slip the hotside off
I forgot to profit somewhere in there!
Sumna*****. Now I need to get the bolt extracted from the hot side, get two bolt holes cleaned/retapped and those studs on the top of the hotside? They have to go! I think I understand why they are there, but fer cryin' out loud, the job would have been way easier if the manifold was hooked to the hotside with bolts and nuts.
So how'd you spend your Thursday night?
Mar 6, 2009, 08:11 AM
#2
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damn dude, that sucks. Im glad I didnt have any problems when I swaped my turbo
So my saga begins here: https://www.evolutionm.net/forums/ev...ce-skills.html
Cliffs Notes: UR o2 housing/downpipe cracks a weld, UR steps up and gets me a new one quickly
Fast forward to yesterday. I get in the new part. Swell, let's go put it on.
The third bolt I get to is seized up! I've had the o2 pipe off once before in January, so I don't know what the heck is going on. So I hit it with some liquid wrench and get one other bolt out to give it some time.
CRACK. Bolt snaps in half. This is the second o2 housing bolt that I've heard of cracking when being removed.
fugity fug fug fug. Now the hotside has to come out in order to get the bolt out.
Getting the hotside off on the X is a bit of a PITA.
1. Remove the UICP
2. Remove the intake
3. Removed the nuts on the exhaust manifold (try not to lose the washers -- but they should be replaced anyway)
4. Remove the nuts on the outer studs on the hot side
All fine and dandy to this point! Good. Here's where the story gets "fun"
5. Remove the bolts holding the hot side to the manifold
or if you're like me these f'ers are seized too. Proceed to ruin three socket heads (make quick trip to lowes for a new 14mm 1/2" socket) while completely stripping the threads off the bolts clean. Hopefully the hot side threads are ok and just need a clean/retap (or else its helicoil time). One of these bolts had previously worked it's way completely out (and this was a week ago)! I have no idea how come it was completely and utterly seized!
6. remove the bracket on the drivers side of the turbo
7. remove the shield on the xfer case
8. remove the buried 14mm bolt that is in the worst possible place ever since you can't get a freaking socket or wrench on it.
9. Give up on the bolt until the morning, spraying a bit more lube on it.
10. Get up early since you can't sleep and in 5 minutes take the bolt that you worked an hour on the night before out.
11. push the turbo back (it's loose now) and pull the manifold off
12. undo the clamp holding the turbo together
13. carefully slip the hotside off
I forgot to profit somewhere in there!
Sumna*****. Now I need to get the bolt extracted from the hot side, get two bolt holes cleaned/retapped and those studs on the top of the hotside? They have to go! I think I understand why they are there, but fer cryin' out loud, the job would have been way easier if the manifold was hooked to the hotside with bolts and nuts.
So how'd you spend your Thursday night?
Cliffs Notes: UR o2 housing/downpipe cracks a weld, UR steps up and gets me a new one quickly
Fast forward to yesterday. I get in the new part. Swell, let's go put it on.
The third bolt I get to is seized up! I've had the o2 pipe off once before in January, so I don't know what the heck is going on. So I hit it with some liquid wrench and get one other bolt out to give it some time.
CRACK. Bolt snaps in half. This is the second o2 housing bolt that I've heard of cracking when being removed.
fugity fug fug fug. Now the hotside has to come out in order to get the bolt out.
Getting the hotside off on the X is a bit of a PITA.
1. Remove the UICP
2. Remove the intake
3. Removed the nuts on the exhaust manifold (try not to lose the washers -- but they should be replaced anyway)
4. Remove the nuts on the outer studs on the hot side
All fine and dandy to this point! Good. Here's where the story gets "fun"
5. Remove the bolts holding the hot side to the manifold
or if you're like me these f'ers are seized too. Proceed to ruin three socket heads (make quick trip to lowes for a new 14mm 1/2" socket) while completely stripping the threads off the bolts clean. Hopefully the hot side threads are ok and just need a clean/retap (or else its helicoil time). One of these bolts had previously worked it's way completely out (and this was a week ago)! I have no idea how come it was completely and utterly seized!
6. remove the bracket on the drivers side of the turbo
7. remove the shield on the xfer case
8. remove the buried 14mm bolt that is in the worst possible place ever since you can't get a freaking socket or wrench on it.
9. Give up on the bolt until the morning, spraying a bit more lube on it.
10. Get up early since you can't sleep and in 5 minutes take the bolt that you worked an hour on the night before out.
11. push the turbo back (it's loose now) and pull the manifold off
12. undo the clamp holding the turbo together
13. carefully slip the hotside off
I forgot to profit somewhere in there!
Sumna*****. Now I need to get the bolt extracted from the hot side, get two bolt holes cleaned/retapped and those studs on the top of the hotside? They have to go! I think I understand why they are there, but fer cryin' out loud, the job would have been way easier if the manifold was hooked to the hotside with bolts and nuts.
So how'd you spend your Thursday night?
Mar 6, 2009, 08:21 AM
#5
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Thanks Goofygrin; you have just convinced me to bypass this mod at all costs!
Sorry about that but you are now commited and there is no turning back. Good luck. I feel certain you will succeed.
Later, Ken
Sorry about that but you are now commited and there is no turning back. Good luck. I feel certain you will succeed.
Later, Ken
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Mar 9, 2009, 05:09 AM
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That sucks man! Helicoil isn't the worst way to go. I'm having the same luck with mine so far. I stripped all the threads off of the o2 sensor after heating and working it back and forth. Same thing happened with all 4 cat pipe bolts. Hopefully, everything else isn't seized also.
Mar 9, 2009, 08:20 PM
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this is honestly very similar to the problems i ran into when i installed my dp/o2 housing. we cross-threaded one of the hot-side threads, as we are re-tapping the hole the bit breaks off inside. as we take off the hot-side 2 of the studs that hold the turbo onto the mani decide to snap, it would not come off with liquid wrench or anything. so installing a dp/o2 on my x cost me a lot more time, effort and money than intended. i don't think i ever want to do this install again in my life lol. . . . hope you get it all sorted out soon. goodluck!
Mar 10, 2009, 01:40 PM
#12
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I tried installing mine on saturday, and had a few bolts seize up. So I had to give up and put it all back together.... Then took it today (only 3 days later!) to a shop... 2 of the bolts were seized up (of the ones i put back on 3 days before!). One of the bolts broke off when removed. Snapped right in half! It took so long to maneuver back there and get the o2 housing off. Re-install of the new pipe was much easier.
150ish for the part, $255 for the install uggggghhh
150ish for the part, $255 for the install uggggghhh
Mar 10, 2009, 08:28 PM
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Maybe they are like Ducati- back in the day, we used to say that instead of Locktite, they used urine and salt-water on their fasteners. Glad it worked out for you in the end, Sean. This has certainly convinced me that if ( 
) I ever mod my X, I'll let Kevin do the heavy lifting (or wrenching, cursing, snapping, tapping, etc).
) I ever mod my X, I'll let Kevin do the heavy lifting (or wrenching, cursing, snapping, tapping, etc).