I am tearing the engine down to rebuild it and I got the manifold/turbo assembly out as one unit. I hosed down all the bolts with lube and let it sit. Damn did that O2 housing and turbo-mani bolts seize up. In the end all I broke was one bolt on the hotside from the mani to the turbo.

It took me 25 drill bits and seven hours to drill it out I even destroyed a snap-on screw extractor (ripped the cutting flutes clean off). In any event....the hole has some messed up threads (the top three) The rest are clean, I ran a tap through it but the metal just isnt there any more.

Do you guys think it will still be alright and the bolt will hold? There is about 3/4 clean threads left.

 

Common occurrence actually with these studs on the turbo related parts. Just get it rethreaded and you should be OK.

 

You will probably be fine...besides what other choice do you have. You will know when you torque it back down to spec.

Next time you have a bolt break off like that...heat the surrounding area up cherry red and then use your stud extractor to get it out. I had that happen on my buddies cobra before. Trust me we tried everything else first, but that was the only way to get the stud out.

 

Believe me....I did. I put an oxy-act torch on that sucker and turned it red-hot. It still would not budge. I eventually got it out with an 8mm tap and that finally bit the metal and turned it back out through the bottom.

I could not believe how hard that bolt was in there.

I want to get this hotside coated too...thats why I would hate to waste the money on it to find out it leaks from the bolt loosening up. Oh well....I may drill the bolt heads and safety wire them.