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Old 04-06-2007, 07:07 AM   #1
Scooby Newbie
Member#: 25195
Join Date: Sep 2002
Chapter/Region: SCIC
2007 STI

Default Please help-Turbo back install gone wrong

So disassembly was going great until we got to the last bolt holding the downpipe to the turbo. All except for one came out with no problem... although the entire bolts were coming out of the turbo, instead of just the nut coming off of the bolt. The last one was being very stubborn about coming out, and when it came out it was completely stripped.

Looks like it may have been crossthreaded when it was originally put together. Anyway, does anybody have any suggestions. There must be left over metal left in the hole. Do you think Subaru dealers would have the bolt in stock? Somebody please help. Would trying to retap the bolt work? What would I need to buy?

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Old 04-06-2007, 07:21 AM   #2
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Location: Cincinnati
2005 Impreza WRX STi


I would order new bolts/nuts from a Subaru dealer (Jamie on NASIOC can easily get these for you). Clean out the suspected hole with a wire brush and try the new bolt. Tap it if you must using a matching tap...look for it on the internet.

In some cases the hole is not crossthreaded like the bolt. For example, I was replacing an O2 sensor on a Corolla. The sensor itself was crossthreaded...threads were toast...but the new sensor went in the exhaust pipe with no problem.
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Old 04-06-2007, 10:07 AM   #3
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You can buy new studs at Autozone. They're .99 a piece. A hell of a lot cheaper than getting one from Subaru.
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Old 04-06-2007, 10:55 AM   #4
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Which hole was it? In a pinch you can run with just four bolts and not have any problems with it sealing.

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Old 04-06-2007, 12:43 PM   #5
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I had to cut one of mine off. +1 for Auto-Zone.
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Old 04-07-2007, 08:31 AM   #6
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2007 STI


Thanks for all the tips. I was able to find studs but I had to call 5 different subie dealers before I found one that actually stocked them. Most dealers do not carry them in stock. Part # is 800910340 and the freaking studs are 8 bucks apiece and do not even come with the nut which is another 2 bucks.

The stripped stud definitely left behind a lot of thread in the hole, and it took some dremmeling and use of a powerdrill and drill bit to clean out the hole before the tap (use a 10 x 1.25 mm tap) would even catch the threads. A huge shard of metal came out and I am glad we retapped the hole. (In fact we went back and retapped all the holes in the vf43 and two of the holes gave off quite a few shavings) Luckily the threads in the hole were not crosstapped and were fine. Some guy at IHI assembling the vf43 must have been lazy or not realized he cross threaded the stud when assembling, and it showed.

We used the double nut method to reinsert the studs and used a lot of anti seize on the exposed part of the stud (After stud is inserted into the turbo) so hopefully the studd will not come loose and the nut will break free if we ever take the Downpipe off again. Who ever installed the studd must have put locktite on the nuts which resulted in the studd coming off instead of the nut during disassembly of the downpipe.

All is good now but be careful with the 07's when install a turboback b/c you will find yourself pulling out the entire stud instead of the nut, despite how much liquid wrench you put on the nut. I was lucky my stud did not break, but apparently the 07's are having issues with turboback installs so make sure you have extra studs, and a tap just in case. Running around with 4 out of 5 probably works, but I did not want to chance it. Rather do it right.
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