Engine/Transmission (1998.5 - 2002) Stud/screw of exhaust manifold broke

[MiB]

Hi guys,
I bought a '99 24V with 255k miles about 9 months ago. It runs solid (carrying a pickup camper) and hasn't given any unexpected problems yet.
When buying, I noticed that a stud/screw of the exhaust manifold was missing. Unfortunately, a piece of it seems stuck in the cylinder head, so it's not enough just to put in a new one. I'll have to tap it and get it out.
So far, it hasn't given any problems, and there was nothing black around the manifold when buying the truck. I noticed yesterday, the first small signs of leakage do appear now. So I figured it's time to react.
My question: Could anyone exactly measure such screw/stud (length and diameter)? I though of putting a "sleeve" into the manifold, so that I can drill in center and then tap in a lefty thread to screw it out. As an alternative, does anybody know if/where I can get 1 single screw of these? I wouldn't want to take off the whole manifold. Just replace that 1 screw.

Thanks,
Michael

 

[RVTRKN]

Drill with the appropriate size drill into the screw and use an easy-out tool. Check out link for a reference for tool set.
http://www.amazon.com/piece-Easy-Screw-Bolt-Extractor/dp/B0002UJNWE

 

[CRodi]

When you get a chance, check out the rest of the stud/bolts. Some of the 12V exhaust manifolds were known to shrink. Not sure if the problem got sorted out by the time the 24V came out on the market.

 

[Joseph Donnelly]

65 mm long flange head M10 x 1.5 thread bolt, 13 mm hex head. 35 mm long spacer sleeve.

 

[MiB]

Thanks Joseph, that helps! Let's see how much is still stuck in there. Don't want to drill too far..
Thanks RVTRKN and Crodi. The other studs look fine so far. I haven't decided yet how to get it out (drill and tap or drill and extract) - I first need to figure out how much I need.
I've had my fair share of broke manifold studs, but that was Volkswagen and back in Europe. I don't have any usable tools for that here. Let's see what my workshop guy has that he can give me.

I'll report once I get it done.

Thanks,
Michael

 

[Bill Stockard]

When drilling out a broken stud, I've had good luck using a reverse twist drill bit. The action of the reverse twist bit may loosen and back the broken stud out while drilling it.

Bill

 

[RVTRKN]

You might want to soak the broken stud over night with a light turbin oil or equivalent , And DO NOT USE CHEAP TOOLS. If you break off a cheap easy out in the stud you will only compound your troubles. The link I provided was only for reference.

 

[MLee]

I have seen these reverse twist drill bits in action and they are the only way to drill out a broken bolt. Soak it up good to loosen the grip it has.

 

[MiB]

Thanks, guys. The reverse drill is a good idea. Didn't think of that.
And yes, no cheap tool bought for me... For tools, whatever I buy, it should be the last one I ever need. My wife rises eyebrows about it, but it's the rule
It's not that urgent, so we're off for a Death Valley trip first for 4 days Oo.

Plan thereafter:
buy a M10x1.5 Banjo bolt (such as this one, 31mm long). Or a shorter one once I know how long the rest of the stud is.
Drill through the head from the thread side.
Put it through the manifold into the cylinder head (don't want to take the manifold off).
Drill with the lefty drill to the mark (65mm - 2 for security margin). I should get to it well once I take of the intake hose.
Hope it worked already, if not, get extractor kit.

 

[MiB]

Hi guys,
so I finally got it done - bought a banjo bolt M10x1.5, drilled it through the head from the thread side, and put it on the manifold. It really worked like a breeze to keep that drill centered. This would have been impossible doing it by hand - the whole thing was about 1cm deep in the head.
I used a 1/8" left handed drill, don't know if a right handed would have worked as well. After about 4mm of drilling, I put the extractor on it - and there it was. Quite a relief that it was without any big trouble.
The slight bypass I had seen was because the lower bolt of the 1st cylinder also got loosened. I screwed it out, and this way, I could easily determine how long the piece in the cylinder head was - turned out to be about 1cm.

Thanks guys for your help - who knows how much the left hand drill helped!

So all set, and off we go to Baja on Monday!
Best,
Michael

 

[SAndreasen]

That banjo bolt was a hell of an idea .

 

[klcammie]

I agree with SAndreasen great idea and one to note for future use with broken bolts. Great write up, reason I stay with this site.

 

[SAndreasen]

Another thing that will center a hole it to take a drill and drill the same size as the bolt diameter and start a hole makes a nice center for the smaller bit .