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Old 06-20-2008, 12:34 AM   #1
99LegacyGT
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Default Broken Head Bolt ! - How to remove?

I was reinstalling the heads, following the torque procedure, I was at the step where you torque them (3-6) to 132 lbs and snap !



I don't see how I can use an easy out here. do I need to take the whole block apart to get to it? or take it to a machine shop?

darn it, trying to save a few bucks I was re-using the head bolts, now it will cost me more.

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Old 06-20-2008, 12:49 AM   #2
BigC
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Well when re-torquing the old bolts, from what I've read 75ft lbs. is adequate. Splitting the block won't help I don't think. Consulting a machine shop would be a good idea.

I had a head bolt strip on me and I had a carbide insert installed in it's place. Obviously if part of the bolt was stuck in the head, it would need to be removed prior to trying to fix it.
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Old 06-20-2008, 12:58 AM   #3
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as long as the threads are in good shape, you should be able to just back it out with the stump left behind in that pic.
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Old 06-20-2008, 01:01 AM   #4
HOLLYW00D
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132 ft/lbs? really? seems awfully high. i can't think of anything that can be done except taking it to a machine shop like BigC stated. sad banana.
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Old 06-20-2008, 01:47 AM   #5
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Cylinder head sequence. this is what I do.

Going in a diagonal motion,
tighten to 22 ftlbs.
Tighten to 51 lbs
Loosen all bolts 180 degrees
Loosen all bolts 180 degrees (yes, you do this twice)
Tighten middle bolts to 27 lbs.
Tighten outer 4 bolts to 170 in-lbs !!!!!!!!! Thats about 14 ft lbs.
tighten all bolts 90 degrees
tighten all bolts 90 degrees (yes you do this twice.

Done.
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Old 06-20-2008, 01:58 AM   #6
ballitch
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I'm with reddevil on this one, who told you 132 ft. lbs.?

I would try to see if you can find some left hand threaded drill bits, you can use those to back out the broken part of the bolt.


~Josh~
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Old 06-20-2008, 02:02 AM   #7
reddevil
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Yeah, it sound to me like you misread teh in-lbs as ft-lbs.!

There is some give or take with my previous #s, but generally they work across the board....
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Old 06-20-2008, 02:31 AM   #8
axelthrasher
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How to remove? - Very carefully.

You most likely will have to drill it out and try to pull it out piece by piece.
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Old 06-20-2008, 02:57 AM   #9
ciper
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Be happy the bolt broke and you didn't strip the block!

BTW I suggest following reddevil's walk through except oil the washers and instead of the last 90 degree torque use 80 foot pounds instead.
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Old 06-20-2008, 03:08 AM   #10
99LegacyGT
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Holy Shiat !

My mistake.
the instructions say ft-lbs for the first 5 steps, then in step 6 it does say 132 in-lbs, my honest mistake, I kept the torque wrench in the ft-lbs !

Guess, I'll have to talk to my machine shop.
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Old 06-20-2008, 03:15 AM   #11
reddevil
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You are not the 1st one not to catch the change.....

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Old 06-20-2008, 03:16 AM   #12
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And as Ciper says, I now also lube all bolts with anti-sieze stuff when installing.
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Old 06-20-2008, 03:48 AM   #13
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Remove the head and just use the EZ-Out at the auto part store, just follow the directions on the package. Or take it into a machine shop and they can take care of it for you also. It's not that hard just make sure you get the right size Ez-Out and when you drill make sure you drill it straight. Either way you have to removal the head to get to it.
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Old 06-20-2008, 09:37 AM   #14
99LegacyGT
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Thanks guys, The head was removed.

I'll talk to my local Machine Shop.

I couldn't sleep well thinking about my stupidity.
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Old 06-20-2008, 12:53 PM   #15
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My favorite method for removing a broken bolt is to drive a 12 point socket over the end of the bolt. I use it for stripped bolts/nuts as well. You'll need to fish through your sockets for one that is tight enough that it takes a hammer to get it down the bolt. Then you can use a rachet to remove it. I prefer to use craftsman sockets because if the socket breaks, I can get a new one. It's a very redneck method, but it works 99% of the time.

However, the head bolts are pretty friggin hard, so this method may not work there.
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Old 06-20-2008, 01:00 PM   #16
charliew
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If the socket doesn't work you might take the broke bolt (to use as a diameter gauge) and find a nut that by trial and error you could put in a socket with some grease or wax to hold it in the socket and hammer it on the remaining piece sticking out of the block. You could also take a file or a counter sink bit and taper the inside of the nut a little to get it started on the stud.
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Old 07-25-2010, 02:54 AM   #17
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Another question - a head bolt stripped clean on me tonight. I used a 1/2" breaker bar with 5 foot cheater bar to torque it off with a proper, hardened 12 point 14mm socket. The first 11 came off with a fight, but the last one took the torque...then stripped. If the damned thing won't let go with the proper tools, how the heck to I get it out now?
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Old 07-25-2010, 11:51 AM   #18
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Never mind - an hour with a grinder and 5 lb "persuader" did the trick.
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Old 07-25-2010, 01:06 PM   #19
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My local Subaru dealer has had this happen to them. They said they've broke upon removal though. My guess is that your local Subaru dealer has had this happen to them as well. Speak with one the the tech's and when you get it out buy him or her a case of beer.
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Old 07-25-2010, 02:48 PM   #20
2milehi
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Throw away all of the old head bolts (assume you torqued them all to 132 ft-lbs). Get replacement head bolts whether new or used.
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Old 01-16-2012, 10:35 PM   #21
ciper
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You can order an entire set of new head bolts from your favorite online Subaru sellers for about 100$

My advice is to reuse them once and dont use them the third time.
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