Snapped bolts in engine - help!

[skilly1]

Can anyone recommend what to do about this problem. Two bolts snapped off, so I tried to remove the other two and they both snapped as well. What is the best way to remove, I was going to do it with a centre punch, drill and extraction tool or am I wasting my time?

I don't have any oxy torch etc.

Or should I remove the manifold and take to garage (removing will be a PITA)

Any advice gratefully received.

[thinfourth2]

Remove manifold and take it to a machine shop do NOT take it to a garage as they are mostly hammering half brains

A machine shop will be able to drill out the bolts on something accurate where as a garage will get busy with a handheld drill

[mwcr85]

thinfourth2 said:

Remove manifold and take it to a machine shop do NOT take it to a garage as they are mostly hammering half brains

A machine shop will be able to drill out the bolts on something accurate where as a garage will get busy with a handheld drill

Partly true, all that is needed is a pillar drill and a tap and die set. (and someone capable of using both). A decent garage should be able to do it, or know someone who can.

[Eggman]

Machine shops aren't the kind of places that tend to open at the weekend, so unless there was one handy for where I worked I'd consider popping down the scrapyard (or Ebay) for a replacement. Might even be cheaper.

When you get to putting it back together, put some spring washers under the manifold nuts to prevent them coming undone.

[VinceFox]

That manifold looks like it'd come off quite easily. Is it a common car?

[skilly1]

Its an MX5, but the manifold fits a turbo so not standard.

Been out and bought this lot, will let you know how it turns out...

[spaximus]

skilly1 said:

Its an MX5, but the manifold fits a turbo so not standard.

Been out and bought this lot, will let you know how it turns out...

Unless you have heat there is no way that the stud extractors will work. NMore probable is you will snap a stud remover in the manifold which will make the job harder still for the machine shop.

[tvrgit]

spaximus said:

Unless you have heat there is no way that the stud extractors will work. NMore probable is you will snap a stud remover in the manifold which will make the job harder still for the machine shop.

This, unless you are very lucky. And if you feel that lucky, put 6 numbers on the lottery and buy yourself a new MX5 or two on Monday.

[bamberwell]

spaximus said:

skilly1 said:

Its an MX5, but the manifold fits a turbo so not standard.

Been out and bought this lot, will let you know how it turns out...

Unless you have heat there is no way that the stud extractors will work. NMore probable is you will snap a stud remover in the manifold which will make the job harder still for the machine shop.

+1 it's all too easy to snap an extractor, which will make it a right arse to remove....

[Pablo Escobar]

Good luck with the extractors, I had a snapped bolt that I drilled, blowtorched and then tried to extract and the fking extractor snapped off inside the bolt.

[steveo3002]

dont use those easy outs , they will snap and make it worse as you wont be able to drill them

the 2 that are proud you could get with a nut mig welded on ...see if anyone local has a mig they could pop round with

Edited by steveo3002 on Saturday 24th March 14:20

[Fort Jefferson]

I doubt the stud extractors will be any good. I'd just drill them out, and re-tap the thread.
It should be quite straight forward if you can take the manifold off.

[thinfourth2]

steveo3002 said:

dont use those easy outs , they will snap and make it worse as you be able to drill them

the 2 that are proud you could get with a nut mig welded on ...see if anyone local has a mig they could pop round with

Yep agree with above.

You need heat and lots of it nothing you can buy in B&Q can supply the amount of heat you need

If you were closer i would say pop round with the manifold and i would get it cherry red and the studs would damn near fall out

[AndrewW-G]

As per others, there is only one safe way to go

1: Remove manifold
2: Take rest of weekend off
3: On Monday take manifold to machine shop (or have somebody else do it, if you have to work) and have them drill out old studs and if required fit helicoil thread inserts
4: Refit

[skilly1]

You were all right ! Stopped using the extractor tool as it was obliviously not up to the job. took off manifold and will get sorted next week.

Should I helicoil anyway as it is stronger in the long run?

Any idea where I would get a gasket from?



You maybe able to see, but all of the manifold bots came out, nut and threaded bar, but one only the nut came off (bottom RHS), does this matter. I presume I just put back in and tighten.



ETA - should I do anything while the car is like this?

[mwcr85]

I'd separate the nuts and studs, or even replace them. A dab of threadlock between the studs/block would stop them coming out, and copper slip on the nuts would make sure they came off easily.

[AndrewW-G]

I'd also have a good clean, and check the condition of any hoses, whilst there is access.

Gasket can be acquired from the likes of MX5 Parts, Mazda dealers or your local motor factors

[Fish981]

Is the manifold gasket not a standard MX5 one? A local motor factor should be able to get one.

[Condi]

Its still a DIY job if you want it to be?

Soak in penetrating oil for as long as possible - overnight at least - then heat with a blow torch until its as hot as you can get it, and finally use stud extractors.

EDIT; for a bit more warmth most hire shops will hire you some proper gear http://www.hss.com/g/55810/Gas-Welding-cutting-Kit...

[kev b]

Take your manifold to a machine shop, they will easily drill out the studs without damaging the threads. This will save the cost of four Helicoils, you did the right thing stopping where you did, patience is the secret.