Engine/Transmission (1998.5 - 2002) new valve cover, torqued too tight

[VolsFan]

I just got my 'cummins 24 valve' valve cover in this afternoon. I put it on, but like a moron, ran into a problem. I didnt know the torque specs for the bolts, I didnt see any info in the Haynes manual. So I just bubba tightened them, and rung the second one from the front off. So has anybody done this or know anybody who has? The truck has been sitting for about 3 weeks until I get it into the shop next week for other work, now I guess this will have to be added to the list. I didnt want to take an ez out to it and risk gettting shavings in the cylinder, guess I should leave well enough alone already and let a mechanic look at it.

 

[benhall]

Have you tried to take the cover off since you've done this? If it broke in a good spot, if there is such a thing, you may be able to get the cover off and use some type of vise grip to take the bolt out.

Ben

 

[VolsFan]

the bolt is broke inside the thread wall, so I cant reach it with vise grips unfortunately. So I can take the cover off and everything, Im just lacking one bolt. I hope the head doesnt have to come off now. If I have the other four tightened can I just plug that one somehow? I guess I'll know by next week anyways at the shop, just trying to get an idea of how bad this will hurt my wallet, i think ive learned my lesson on doing anything mechanical, even something as miniscule as this.

 

[rkressg]

If you disassemble the rockers and valve train around the broken bolt, you might be able to get at it with an ez-out.

 

[ABorgardt]

If all your worried about is any shavings, you can try putting grease on the ex out. that should attract any shavings that there might be.

 

[PRout]

Lucky its towards the front. You might be able to use a bunch of rags to absorb/wipe ALL of the oil out of the area and if you can get it dry enough, cover the rest of the head and holes so particles don't contaminate anywhere else. With good lighting and from a comfortable position, use a very small, new, high quality drill bit (use a touch of wax or grease on the tip) and go VERY slow and careful to center up the pilot hole, then step drill it out to the required size for an EZout. Vacuum well. Remove the bolt and re-vacuum the head extremely well, making sure none of the rockers, etc have any pieces hidden in their contact areas.

Visually inspect thoroughly with good lighting & a mirror. Replace the cover. Run it & change the oil & filter. You should be ok. Then, be glad it wasn't cylinder #5 or 6 and buy some good torque wrenches and use them on everything per the "official service manual" specs.

In this case, page 9-263 of the 2000 service manual specifies 18 ft/lbs or 216 inch/lbs for valve cover bolts and to start at the middle and work out towards the ends.

Hey, it's like we say out at work. "The best way to learn is to break it". But then again, its mostly the software people that use that saying.

 

[VolsFan]

sounds like a good idea. Yeah, I guess if there is a positive out of this its that it is towards the front and it is a learning experience, and that I need a good set of torque wrenches. Thanks, now I dont feel as bad. Heck, Im 23, and if learning experiences make you wiser I'm going to be one smart old timer when I'm older...

 

[DCreed]

if you can find them reverse drills may remove it while drilling and wont even need the easyout. anyway you go just be sure you dont drill THROUGH the bolt into the head! use a spare bolt against the one you broke to measure safe depth.