I need an "odds maker" on this one!
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan
I need an "odds maker" on this one!
What are the odds & ultimate consequences, worse case, of breaking the Torx head fasteners that attach the pipe over the passenger side valve cover to the intake manifold? I've replaced the drivers side valve cover gasket. Not a big deal, lots of stuff to move around, but nothing broke! I've sprayed the fasteners down with a good peneratant, but doubt that it will ever get to the threads. I've broken a wrench trying to remove the Torx fasteners. I tried to use my Milwaukee driver, but it was no help. I assume the fasteners are grade 8, but it is still possible to break them. Has anyone ever just Sazall the pipe in two places so that the VC can be lifted straight off, gasket replaced, then reconnect the cut out piece. Weld, braze, or use some kind of heat resistant exhaust putty to re attach. I've sold the car with the stipulation that the VC leak be fixed. So I don't want to spend $$ or break it. Twenty thousand miles on the car and almost nothing has ever been removed or touched. Any thoughts? Thanks.
Race Director
Joined: Aug 2000
Posts: 11,470
Likes: 764
so, where did you break the torx bolt - at the intake or exhaust manifold? as far as cutting that thing in two places and using welding, brazing, or high temp putty, well, never heard of such a thing. not saying something like that can't be done, it might take some design and engineering up front work. anything's possible. I would think welding/brazing is out since you would have to go 360 around the tube. from the sound of things, I'd guess you broke the bolt at the intake side - dissimilar metals - steel/aluminum galvanic corrosion. do you have any threads of the bolt showing or any part of the shank? I've had some limited success drilling down thru the center of some bolts. my gut feeling is you're going to have work for this repair. I hate when crap like this happens!!! good luck - 
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan
so, where did you break the torx bolt - at the intake or exhaust manifold? as far as cutting that thing in two places and using welding, brazing, or high temp putty, well, never heard of such a thing. not saying something like that can't be done, it might take some design and engineering up front work. anything's possible. I would think welding/brazing is out since you would have to go 360 around the tube. from the sound of things, I'd guess you broke the bolt at the intake side - dissimilar metals - steel/aluminum galvanic corrosion. do you have any threads of the bolt showing or any part of the shank? I've had some limited success drilling down thru the center of some bolts. my gut feeling is you're going to have work for this repair. I hate when crap like this happens!!! good luck -
Melting Slicks
Joined: May 2014
Posts: 2,895
Likes: 592
From: New Port Richey FL
I feel your pain but the most simple way that I have used is a quality Torts socket and a Impact 3/8 gun, as suggested above a little bit of heat goes a long way and wouldn't hurt.
for some reason even when these cars were new those bolts loved to shatter Torx bits, and using a braker bars seemed to want to twist the tube off of the Exhaust manifold and slap the sockets
Last edited by s carter; Jun 29, 2015 at 09:07 PM.
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan
Kind'a did that with my driver tool. Hard to add much heat with the distributor and fuel rail being right there. Although that pipe gets quite hot each time the engine is running. Thanks for your input.
Race Director
Joined: Mar 2015
Posts: 15,926
Likes: 579
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan
Have you ever snapped one off? Thanks
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
Top 10 Most Expensive Corvettes Ever Sold on Bring A Trailer
Brett Foote
10 Things Every Corvette Owner Needs (2026 Edition)
Michael S. Palmer
8 Most "Only Corvette Owners Understand" Quirks and Problems
Pouria Savadkouei
10 Reasons the C6 Z06 is Still A Performance Benchmark After 20 Years
Joe Kucinski
How Much Horsepower Every Corvette Engine "LOST" in 1972
Joe Kucinski
Top 10 DOs and DON'Ts for Protecting Your Convertible Top!
Michael S. Palmer
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Melting Slicks
Joined: May 2014
Posts: 2,895
Likes: 592
From: New Port Richey FL
I take it from one of your post that you have one of the Semi rare ones that has just 2 bolts by the plenum and a clamp by the manifold, Either way if your dealing with the ones by the Plenum a good socket and impact (but don't install with impact)does the trick they tend to like to come out the ones by the manifold that's another story.
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan
No but I have killed many Torx bits and stripped out the centers once or twice, than you wined up using Vise grips and ruin the bolts getting them out.
I take it from one of your post that you have one of the Semi rare ones that has just 2 bolts by the plenum and a clamp by the manifold, Either way if your dealing with the ones by the Plenum a good socket and impact (but don't install with impact)does the trick they tend to like to come out the ones by the manifold that's another story.
I take it from one of your post that you have one of the Semi rare ones that has just 2 bolts by the plenum and a clamp by the manifold, Either way if your dealing with the ones by the Plenum a good socket and impact (but don't install with impact)does the trick they tend to like to come out the ones by the manifold that's another story.
Semi rare, I wasn't aware that there is a different configeration, than the one I have? Please clarify.
Melting Slicks
Joined: May 2014
Posts: 2,895
Likes: 592
From: New Port Richey FL
Thanks for that information. This Vette is a Dec 85 build with the cast iron heads. Yes two bolts at the top intake manifold end, and a SS one time use clamp at the lower ex manifold end. The same as the one that is used on the small pipe that goes to the main cat.
Semi rare, I wasn't aware that there is a different configeration, than the one I have? Please clarify.
Semi rare, I wasn't aware that there is a different configeration, than the one I have? Please clarify.
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan
Thread Starter
Instructor
Joined: Jun 2013
Posts: 138
Likes: 4
From: Apollo Beach Florida & Michigan