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Message started by Bubba1 on 01/17/13 at 17:01:56

Title: Head cover problem broken bolt
Post by Bubba1 on 01/17/13 at 17:01:56

So I started to remove my head cover to do the plug oil leak deal, when I got to the L125 bolt I realized it was loose and had been broken off by the PO it was missing about 1/8" of threads that I assume are still down in the cylinder ! So my question is what are my options, can I drill it out ? Put a heli coil in? Will it matter that much if that bolt is missing? Please help thanks so much

Title: Re: Head cover problem broken bolt
Post by verslagen1 on 01/17/13 at 17:05:41

sure they didn't put the wrong bolt in?

I wouldn't try to drill it out

and breaking off the last 1/8 is probably remote.

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/17/13 at 17:42:29

I guess that's possible? Thing is it won't catch at all so you cannot tighten it

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/17/13 at 17:43:11

Any chance someone knows exact length of that bolt?

Title: Re: Head cover problem broken bolt
Post by verslagen1 on 01/17/13 at 17:48:40

125mm

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/17/13 at 17:49:56

Dang your good let me measure

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/17/13 at 17:50:45

Oh is that why its the 125 bolt ? Boy nothing gets past me

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/17/13 at 18:02:18

Well it's aprox 110mm long now and def sheared off so there's somewhere about 15mm of thread stuck down in the hole

Title: Re: Head cover problem broken bolt
Post by raydawg on 01/17/13 at 21:03:26

I remove damage bolts as a living on commercial aircraft, and I can't tell you how critical it is to extract on the first try. Key is drill speed, slow and steady. You should be returning, in one piece, the removed material as a sqigly worm...if you go too fast, you harden the metal, making it more difficult to grab and ease out. I have removed stainless and titanium, its hard, but doable, and some of the areas/location I have to work leave a lot to desire. Remember, make the first bite solid and true, you jimmy it, you might have to drill it out, no fun....

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/18/13 at 05:00:36

Is there something specific you could recommend like drill bit size and extractor size? I've used plenty of easy outs but never seen one that long ! Any help is really appreciated

Title: Re: Head cover problem broken bolt
Post by justin_o_guy2 on 01/18/13 at 08:19:24

Before any "extracting" gets done Id suggest a probe to the bottom of the hole & a measurement, to be certain theres really a piece of stuff in there.
If you have enough threads available to achieve the clamping forces you need w/o going in digging & drilling, you mite just be ahead to put a bolt in & go.

+1,... Serow...

Title: Re: Head cover problem broken bolt
Post by wambr on 01/18/13 at 09:24:26

I am also so I think the previous owner of the most likely set a non-standard screws no need to try to extract may rest (although I don't think so) part. I think you have to leave everything as it is.

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/18/13 at 09:57:54

Thing is I tried a longer bolt with same thread it will not grab at all so it can't be tightened the way it is there is def something stuck it the threads and must be near or at the top of the threads not allowing a bolt to screw In at all

Title: Re: Head cover problem broken bolt
Post by engineer on 01/18/13 at 17:20:55

There may be just one damaged thread or a burr or foreign material that makes threading impossible. Justin_o_guy2 is right, probe the hole with a wire or something and make some careful measurements. If you have compressed air and some tubing try and blast out any dirt down in there.

If the hole is clear, I would run a tap through it before I drilled it for nonstandard threads. When a tap doesn't reach you can always weld a piece of round stock to the end of it. I have had some success using an old bolt with a notch ground in it. Make the notch perpendicular to the leading edge of the threads. If a thread is just bent or rolled over from a PO crudely trying to get a bolt started then the bolt might straighten it out well enough to get the good bolt started in the threads. Once the threads are clean and straightened then they will not cause anymore problems, just be very careful when tightening it.

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/18/13 at 19:04:38

Will try your suggestions and then get back with you guys when I know for sure thanks

Title: Re: Head cover problem broken bolt
Post by Bubba1 on 01/18/13 at 19:23:38

Def has the bolt stuck down there in the threads no question so now my question is does this bolt only hold the headcover down or actually hold the head down because I could just tap the very top of the hole for a slightly larger shorter bolt ! That will work I it is just used to hole the head cover tight

Title: Re: Head cover problem broken bolt
Post by wambr on 01/18/13 at 21:35:58

I'm so deep in the engine wasn't putting my, but as far as I understand the cylinder head is attached to the cylinder on 4 studs and nuts and 2 bolts from the front and from behind...and bolts in the cover of the cylinder head is fixed only the cylinder head cover...