Broken Header bolt.. what am I looking at here?

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Jan 10, 2006 | 05:10 PM

REDLYNER

Thread Starter

Burning Brakes

Joined: Mar 2002

Posts: 1,215

Likes: 1

From: Mt Isle Harbor NC

Broken Header bolt.. what am I looking at here?

I snapped a header bolt when I put on my Kooks LT's. The end of the screw is in the head, so I can't get to it myself.. so it must be tapped out (hopefully).

It looks like I have two options:

1. Take everything apart myself, and deliver the head to someone who can back it out, then re-install everything hopefully the way I found it

2. Take it to a shop and have them remove the driver's side head, hopefully be able to back out the bolt, then re-install the head and other parts.

What kind of time am I looking at to take it off myself and what kind of dollars am I looking at to have a pro do it?

THANKS!!!!!!!!!!

Jan 10, 2006 | 07:55 PM

SpeedyZ

Drifting

Joined: Oct 2004

Posts: 1,384

Likes: 8

From: Southwest Virginia

Ouch!!!

Hate when that happened!

Any idea why the bolt broke, just too tight, cross threaded, bottomed out, or...? As long as it is not cross threaded or bottomed out it will probably come out pretty easy. Which bolt? It may be able to be removed while still on the car, I have remove a lot of exhaust bolts while still on the car/truck, but this is a Vette and they don't have much room so that may not be an option.

Heads are fairly easy to do on these cars. I'm guessing if you take your time it will take less than 4 hours to remove. Since your an 01 it will take another hour or two scraping those %$&*#$@%*# factory fiber gaskets off the head and block! Probably another 4-5 hours reinstalling if you take your time and lots of breaks. Intake, alternator, and head is about all you will need to remove. You can get one head gasket and a single side of bolts and reuse the intake gaskets, so price will probably less than $100 doing it yourself. Just be sure you clean the block and head really good, those fiber gaskets are a pain to get them all off!

You know this would be a good reason to upgrade to AFR heads!

Good luck!

Jan 10, 2006 | 08:04 PM

MgKenny

Instructor

Joined: Sep 2005

Posts: 110

Likes: 0

From: Sunrise, Florida

I think I'd be more inclined to buy a right angle drill and a REALLY good drill bit (with a good spring loaded center punch to start you off) and drill a pilot hole in the center of that broken bolt and try to "easy out" it out before I would tear the heads off.

Of coarse, it could be a "sign from god" that you NEED better heads.

This of coarse depends upon the amount of "green" in your wallet.

Let us know how it turns out.

I feel for you!

Ken

Jan 10, 2006 | 10:19 PM

Lovin It!!! - C5

Racer

Joined: Oct 2005

Posts: 351

Likes: 0

From: Haw River North Carolina

Unless your ready to buy a new set of heads, I'd pull em myself (if your mechanically so inclined) and have a shop remove the bolt.

Just not worth the risk unless your ready to upgrade. I'd personally rather do it right the first time than be pi#$ed off that I made it worse. Just my $.02

Take it easy and good luck with your fix. I feel your pain.

Jan 10, 2006 | 10:52 PM

SteveDoten

Le Mans Master

Joined: Sep 2003

Posts: 6,276

Likes: 227

From: Farmington CT

Cruise-In VII Veteran

i recently replaced a rotted manifold on a 98 Ford Expedition w/ the 5.4, one of the studs had snapped in the head, i cut a flange off the cast iron manifold(sawzall)and used a centering drill fixture w/ an 18 inch drill bit to get a straight shot(the frame kept the rt angle w/ a shortened bit from getting it)

i've never seen this on a lsx motor, the only things the fords are good for is making $$ fixing them

i'm guessing this is the very aft bolt

, can you grab a corner of the threaded part w/ a punch and back it out?

Last edited by SteveDoten; Jan 10, 2006 at 10:54 PM.

Jan 10, 2006 | 11:07 PM

unstressed

Burning Brakes

Joined: Jan 2003

Posts: 1,207

Likes: 27

From: Sun Diego CA

Remove the header, and find a friend with a mig welder. Since the head is aluminum and the bolt is steel, you can add metal to the broken bolt until you can either grab it, or weld a nut on the end.

Go slowlythen go even slower. Patience is key.

The heat from the welder will also help loosen the remaining bolt in the head.

Go slowly.

I've done this before and it always works for me.

Did I mention to go slowly?

Good luck whatever method you choose.

Jan 10, 2006 | 11:19 PM

Wisdom

Racer

Joined: Sep 2004

Posts: 486

Likes: 1

From: Houston TX

I've broken a few bolts before and I've never had luck drilling into whatever was left in the hole. Even with a punch I couldn't get the drill to stay centered, whether using a small or larger drill bit. So the easy-out approach isn't something that I would try. I'd be more inclined to take out the header and bring it somewhere for bolt removal. Or - if you're ambitious - take out the header so you can have clear access at the broken bolt. Either way it's take out the bad header. Best of luck to you. You'll get it done. If you were mechanically inclined enough to think about listing your options then I think you're inclined enough to recover the header.

- Wisdom

Jan 10, 2006 | 11:37 PM

REDLYNER

Thread Starter

Burning Brakes

Joined: Mar 2002

Posts: 1,215

Likes: 1

From: Mt Isle Harbor NC

I think I am going to try and take the head off myself. I all but did that to get these headers on anyway. I guess the worst the could happen is that I can't do it, so I'd have to take it to a shop anyway. If I had the pocket change, I would be all over a new set of 205's.

Thanks!