Header Install Problem. HELP!
Thread Starter
Advanced
Joined: Nov 2013
Posts: 61
Likes: 3
From: San Diego, CA
Header Install Problem. HELP!
Recently purchased some LG Street series headers for my 04 Z06. After a few hours of wrestling with the stock parts and getting the new parts in I was torquing down the stock header bolts and was on my last one, passenger side rear bolt broke as I was tightening it. Needless to say a big gasp and shock hit me. The bolt broke flush with the head. I've tried to drill it out with reverse bits, got a extractor kit and one of the extractors broke off in the bolt. So now I have a hard metal extractor bolt stuck in my header bolt. I'm lost and don't know what to do now. Any ideas or advice would be greatly appreciated.
Burning Brakes
Joined: Oct 2004
Posts: 984
Likes: 23
From: Florence SC
you will need a carbide bit to drill it now, it will be best to pull the head and carry it to a machine shop for proper removal. Be careful you can intercourse up the head even worse if a drill gets to the aluminum. 
Melting Slicks
Joined: Mar 2002
Posts: 2,203
Likes: 63
From: Staten Island NY
I replaced a set of headers on a C5 that had a broken bolt in front and it wasnt leaking at all even after lots of hard driving.
If you used the stock type gaskets I would finish the job and start it up and drive it. See if its even leaking before you pull the head.
If you used the stock type gaskets I would finish the job and start it up and drive it. See if its even leaking before you pull the head.
Racer
Joined: Apr 2013
Posts: 255
Likes: 1
From: Enterprise AL
I did the SAME thing about two weeks ago. Broke the passenger side forward most bolt. Needless to say I was bummed. I couldn't get it out either. Ended up going to a couple exhaust shops, both said it was likely the head would have to get pulled, because if it was cross threaded, and enough torque to snap a bolt, it would have to be fixed. So I put my car up. I am going a bit extreme to have it fixed, and sold my motorcycle (I'd already put all my play money into headers) and am now having a cam put in this week, and while they're in there, they are going to pull the head and fix the bolt.
I feel for ya man. Best of luck.
I feel for ya man. Best of luck.
Thread Starter
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Joined: Nov 2013
Posts: 61
Likes: 3
From: San Diego, CA
Went to a local hardware store to see if they had some carbide bits, no luck. I picked up some cobalt bits but again no luck. I'm hoping I don't have to pull the head as that's a little bit out of my comfort zone. I'm hesitant to drive the car because Bobby from LG said it can do some serious damage. This project went from having fun simple day to a nightmare. Does the Home Depot or Lowes carry carbide tips? I live in Hawaii and everything seems be more difficult to find out here. I don't even think there are any performance shops around. Thanks for the replies.
Thread Starter
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Joined: Nov 2013
Posts: 61
Likes: 3
From: San Diego, CA
Any ideas on cost if I do have to pull the head?
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Racer
Joined: Apr 2013
Posts: 255
Likes: 1
From: Enterprise AL
The few shops I asked said it'd be about four hours or more @ $100 or so an hour for labor. Then gaskets, etc. So, yeah, I bet easily 5-6 hundred bucks. Since I'm having a cam put in, and they're already down in there, it's only a bit more work to pull the head, so they're only charging me like, another $300 or so.
Instructor
Joined: Nov 2013
Posts: 142
Likes: 0
From: Christiansburg Virginia
Go online to McMaster-Carr or MSC Industrial Supply. They will ship right to you. But like the others said, a machine shop is your best bet. They will clamp the head in a holding jig and use a milling machine to remove it. A hand held drill - no matter what kind of bit you have - is going to "walk" - off center. Then you are really screwed. You'll have to replace the head or have it welded, drilled and re-tapped.
If you can't pull the head (for comfort / skill or whatever reasons) have it towed to a good shop. It's going to be cheaper in the long run. Forty plus years auto / truck / industrial maintenance speaking. Sorry for your problem.
If you can't pull the head (for comfort / skill or whatever reasons) have it towed to a good shop. It's going to be cheaper in the long run. Forty plus years auto / truck / industrial maintenance speaking. Sorry for your problem.
Thread Starter
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Joined: Nov 2013
Posts: 61
Likes: 3
From: San Diego, CA
I went to the auto hobby shop on base today and talked to one of the master mechanics their. He didn't really have anything to say other than what I've tried. I'll probably just pull the head and take it to a shop. If I had the money I'd say screw it and get a set of new/better heads but my wife would kill me and I kinda like having her on my good side.
Thanks for all the help gentlemen.
Thanks for all the help gentlemen.
Burning Brakes
Joined: Feb 2008
Posts: 949
Likes: 1
From: Tampa fl
St. Jude Donor '14
Its not a big deal to take the heads off. Just start taking stuff off and take your time. label things if you need to. If your comfortable enough to take a drill to them you should be fine. Your pocket will thank you. Save the money, take it off and a shop will charge you MUCH less.
Safety Car
Joined: Jan 2012
Posts: 3,953
Likes: 520
From: Da U.P.
