HELP!! Broken injector need help

[diesellund]

Broken injector need help

I was pulling my injectors and pump. Whin I got to the last injector all the way back by the fire wall. I was using a puller that tightens to the top and pushes off the head and the injector pulled apart. Does anybody Know how to get the other pice out of the head? Please help.

Dodge 1993 W350 4x4 5speed inercooled

 

[BCaldwell]

diesellund welcome to the group sorry to hear about the injector, you may be able to get a small heelbar between the head and the injector and pop it out that way bill

 

[diesellund]

No the injector has split in two pieces. At the middle wear they are tread togeather

 

[BushWakr - RIP]

diesellund,



I've sent you a PM to try and help. Let us know how you make out.



Anybody ??? Ideas ????? step up and post??



Bob.

 

[formula]

Maybe you could use a screw extractor bit and jam it into the stuck half of the injector and pull it that way. Of course this will most likely destroy the insides of the injector, I'm assuming it's broken anyway.



Sean

 

[Case500D]

Do you have a welder?

diesellund,



If you have a welder and feel comfortable doing this, here is an idea. Find a 6" piece of all thread that will just fit into the holw of the piece of injector stuck in the head. The tack weld the all thread to the broken piece. Then take a weight or big socket and make a slide hammer out of the all thread and "pop" the broken piece out. The heat from welding ought to help loosen the broken piece. You may break the weld, but be persistant. Make sure you don't get anything too hot while welding. Just an idea that I have used to pull numerous broken things off and/or out of old tractors. If you need a stock injector, I have one you can have. PM me and I will get it off to you.



Jeremy

 

[Philip]

All thread is not a hard material. I would find the longest hardened bolt you can and use it instead of all thread. If you try Case500D suggestion.



All thread is brittle to begin with. The heat from welding will weaken it even more. A good hard bolt will hold up better in this use. This is a one shot deal. Once you drive something in there and weld it. If it breaks off when you try to pull. Then you will be in deep ####. The next step would be to drill out the broken piece to try agin.



If you try formula's idea do not use one of the long spiral type of extractors. They break off real easy. find a set that are used for broken pipe and allen bolts. They are very short.



This is not the type to use.

http://www.kctools.com.au/kctools/im080001.htm



You would not be able to get it out afterwards. You can not weld to it. The only way to get one out is with an EDM machne.



Go to this site and type in multi-spline extractors. Theses are the type you sould use if you try this route.



http://www.mcmaster.com/

 

[BushWakr - RIP]

diesellund,



I had a chance to talk to Piers today, regarding your problem.

He suggested 3 options.

1) Grind/remove the indexing ball on the top/side of the injector part that came out, (assuming you have some thread left) then thread the piece back down into the broke part. Turn it in snug and have at it again. Only by removing the indexing ball can you get it to go in/down deep enough.



2) Place a large wad of rags on top of the injector hole (Bill Caldwell suggest adding a small piece of plywood here) and turn the engine over. The compression should pop it out like a bad tooth.



3) Here's the ugly one... ... ... pull the head and smack it out... sorry, I hated to even hear this one, never mind do it myself.



Well, that's all us rocket scientists could come up with on short notice.



Hope that helps, and let us know how you make out. .



Bob.

 

[Lil' Dog]

The compression idea is what I was thinking. With 400Psi compression in these things it should come out. But the injector is only about 7mm across at the tip so with math thats about. . mm

25 Lbs force. . Might not be enough.



Try the thread idea from PIERS and lots of Liquid Wrench or NutCracker in and around the stuck part. Some heat wouldn't hurt, but you don't want to crack the head.



Good Luck



J-eh

 

[diesellund]

I tried turning the engine over but it did not move. The broken part that is still in the head is about 1/4 inch. from the top of the hole. It has to be just about out I'm thinking of welding a steal rod to it and try pulling. The reason I can't tread the top piece in and make it stay is the injector case has split on the threads. I've welded in worse spots but I'm still concerned.

 

[BushWakr - RIP]

If you plan to use the welding technique then slobber some grease on the areas were you do NOT want any splatter to stick too. That way you'll have a fighting chance to prevent any blobs of metal in the way of the new injector when it goes in. I think grease will work, unless someone with more experience has a better idea to prevent welding splatter from sticking to surrounding surfaces. You'll also need a good hard rod or whatever to weld in there so it won't break off or bend on you. .



BTW, if you are successful in getting this thing out be sure to post this problem/solution in the "Best tips for new 1st Gen Owners" thread. You may save someone elses bacon down the road with this one.





Good luck...



Bob.

 

[bighammer]

Originally posted by Lil' Dog

The compression idea is what I was thinking. With 400Psi compression in these things it should come out. But the injector is only about 7mm across at the tip so with math thats about. . mm

25 Lbs force. . Might not be enough.

Might be like a 25# hammer rappin' from the inside. I like the idea of letting the engine compression do the work here.

 

[Dman]

Broken injector

I also like the compression idea. Just turning it over with the starter for a minute or so. Some heat sounds good to - If your afraid to use a torch for fear of overheating - use a propane torch - I don't think you could put too much heat in with that. Good Luck & Merry Christmas to All.



Dave Williams

 

[hdm48]

OK guys. here is one that is WAAYYY out in left field but has worked for me. If you can't get to it to weld, try attaching the stinger (arc welder) to a bolt and slowly lower it till it arcs. As it starts to melt the materials, let it come in contact. It may take a couple of tries to get it right, but it should make a strong enough connection to pop it out.

I have done this with hidden bearings and it has worked for me.

Just make sure you don't let it come in contact with the head or anything else.

I'm sure you would rather try anything other than pull the head. You might also try some liquid nitrogen aimed at the injector. It will shrink faster than the head. But you will need something to grab it with.

Just a couple ideas. I hope you get it out.



--dave--

 

[diesellund]

My dad got the injector out by screwing the top back on intell it seated. and then used the puller. Thank you all for your info.

 

[Tim1]

welding

Hey bud, if you decide to weld a bolt to the broken piece, use a new dry 3\32 or 1\8 rod of 7018! This rod is strong only if you can only manage a small tack, it will come out. Just my experience with 7018! Tim Good luck.