Was installing my open dump downpipe and got 4 out of 5 bolts out fine. The easiest bolt to grab with the socket cracked loose and spun out 3 rotations. The bolt seized up, I soaked it in pb blaster and used a torch to try and crack it loose until it finally snapped. The snapped bolt is about 1/8 inch inside the o2 housing and Is still threaded in. My protune is on Saturday so I need to get this car to a shop ASAP Tommorow morning. I'm letting the shop do the work but of course gonna be there to watch and make sure they aren't doing too much extra work to hustle me out money. What would be the routine to solving this headache? I was reading multiple posts already and some users drilled the bolt out while still in the engine bay, some took the hot side turbo out and also the exhaust manifold out and vice versa.

 

Edit, the bolt that snapped is the highest bolt on the o2 housing (top bolt)

 

Mine did the same. The only thing I could do was to remove the hot side of the turbo from the compressor wheel and exhaust mani. I then took it to a machine shop to be drilled out and re tapped for $50.

It's pretty easy to remove the hot side, no coolant or oil lines need to be removed.

Good luck

 

Would a ordinary auto shop be able to drill and tap correctly or would it be a better option to bring it to a machine shop? Also does the exhaust mani need to be removed or just unbolt where it meets the turbo? What consists of the hot side of a turbo

 

do you have a dremel?

just buy a long burr and dremel er out. i did it.

 

my o2 sensor on the cat went throught the same except when i pulled it out it was all stripped.. both on the sensor and the cat.. now i have to buy a new sensor to install back on the test pipe.. and the sensor is close to $500 at the dealership

 

do not buy it there. Hop on one of the many Facebook groups. Even if you dont have Facebook. make an account. Someone will sell you a cheap one. bought mine for $60

 

Dont buy walker o2 sensors for the Evo X. A lot of them have problems with the heater circuit.

 

Total noob here. Would it then be somewhat of a fail safe to remove the hotside and manifold with the DP attached? Or is it not possible to remove the two together?

Im dreading my stock 08 exhaust system when I upgrade.

 

I was able to remove the hot side from the exaust mani no problem. Its 4 bolts plus some support bolts, two I think. It was a while ago.