Engine/Transmission (1994 - 1998) Head Bolt Buster - Help?

[fleahead]

Head Bolt Busted - Help?

I had the thread about "Lost Coolant", and I just spotted the problem. The 4th head bolt from the front (passenger side), is twisted off. It looks like it's been broke a long time. I've had the truck for a year and never noticed it. Mysteriously, the previous owner (one owner used truck) denies ever having had any work on the head. Anyway, there is some leakage around the exhaust flange there. Anyone have any suggestions or experience on getting the old bolt out? I'm only a basic mechanic, and not sure of what tools would be needed and what the procedure would be. Fortunately, the bolt is clear from any obstructions and access would be easy. Any idea what a garage might charge to drill it out and replace it?

 

[DSiemens]

Several ways to tackle this problem. Is the bolt broken off flush or can you get a vicegrip on it? If it is flush or slightly below, you can weld a nut to the bolt and then turn it out. Those bolts are fairly hard to drill. Snap On sells a unique type of drill bit that will drill a hole so an easy out could also be used. Last resort would be to pull the head.



Dan

 

[HoleshotHolset]

Be careful with easy-outs/screw extractors...



When you drill out the bolt/stud and stuff an easy-out in there... it can expand the bolt so that it binds against the block... then you have a heck of a time even turning it.



A machine shop friend of mine will usually drill a hole and pound a torx bit into the bolt/stud... this minimizes the amount that the bolt/stud will expand and they'll usually come out pretty easily.



Matt

 

[PUMPERDUDE]

Don't forget to give it a good soaking with penetrating oil... PB blaster or Kroil can work wonders. I would soak it,then pound it a bit with a punch just to work the oil in and break any rust. Then drill it and try an easy out... . If you've been living right,it'l come right out. Good luck.

 

[fleahead]

More Info

Well, I took it over to a certified diesel mechanic and he says it wasn't twisted off, rather it popped off. Since it only has 105K on it, he thinks I should contact Dodge and try to get them to stand behind it, since the Cummins warrentee is 7/100k. (In actuality, I have a 10% error in the speedometer, and if I calculate it out, I only have about 90K actual miles). Has anyone heard of anything like this happening? How about any luck with Dodge showing mercy?

 

[HoleshotHolset]

How about any luck with Dodge showing mercy?

Take it to a dealer that is known to be 'cool' about situations like this. There are a lot of dealers out there that will try to stick it to their customers 6 ways to Sunday... be prepared for that.



Matt

 

[mechanic]

headbolt

10/4 on the dealer selection. I used to work for a dealership in my younger years when they were better then now. And it is important to get with one who will be reasonable with you. I have seen head bolts and main cap bolts pop their heads off. But the headbolts were in a GM 5. 7 diesel. They were bad about that. But all I ever had to do was to use a sharp screwdriver and screw it out, then install another bolt and tighten it.



Several companies make a left hand drill bit that will often spin the bolt out of the hole while drilling. If the bolt is to hard for a standard bit, Rodman makes a drill set that will drill holes in a standard bit. It looks like snake oil, but I bought a set and they work. Look up Rodman on the net.



Good luck with the dealer.