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Old 02-27-2012, 01:20 AM   #1
Scubaru23
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Default Broken Valve Cover Gasket Bolt

So I was replacing my valve cover gasket and I swear it's just my luck that I broke a bolt. I need suggestions on how to get it out or what I'm going to have to do to fix it. It's the bottom right bolt. #4 on the picture. I can't get a drill down the far because of the car's frame. Basically no part of the threads are showing and the bolt broke pretty much where the threads begin. I'm at a loss of what to do. Thanks!
http://i1018.photobucket.com/albums/...Cover056-1.jpg
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Old 02-27-2012, 10:02 AM   #2
ride5000
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wow, that really sucks. how the hell did you break this bolt?

you may be pulling an engine. time for a clutch, timing belt, flywheel, etc!

is there ANY way to grab the rest of the bolt? take off the cover. can you clamp on a pair of vice grips?

can a nut be welded onto the stub?
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Old 02-27-2012, 10:09 AM   #3
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take the cover off and unscrew it...common issue....when they are over torqued.....
torque is very little---i dont have my fsm available now....but IIRC it is 6.6ft-lbs...which isnt much

no gorilla torque is needed or wanted on these
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Old 02-27-2012, 01:18 PM   #4
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Quote:
Originally Posted by Scubaru23
So I was replacing my valve cover gasket and I swear it's just my luck that I broke a bolt. I need suggestions on how to get it out or what I'm going to have to do to fix it. It's the bottom right bolt. #4 on the picture. I can't get a drill down the far because of the car's frame. Basically no part of the threads are showing and the bolt broke pretty much where the threads begin. I'm at a loss of what to do. Thanks!
http://i1018.photobucket.com/albums/...Cover056-1.jpg
I did this exact same thing. I've definitely learned my lesson since, but I ended up taking my head off and sending it to a machine shop. After trying to use an extractor bit first, the bit broke off in the head.. so I had no other option.
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Old 02-27-2012, 07:06 PM   #5
Scubaru23
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So I took the valve cover off and there isn't any part of the bolt that's sticking out. Basically, I'm at a loss of what to do. I definitely want this fix to be as cheap as possible.
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Old 02-27-2012, 07:27 PM   #6
rextech255
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Originally Posted by Scubaru23 View Post
So I took the valve cover off and there isn't any part of the bolt that's sticking out. Basically, I'm at a loss of what to do. I definitely want this fix to be as cheap as possible.
What I would do, is get a right angle pick and try to get the broken bolt loose. Go around the outside of the broke bolt in counterclockwise circles. You may be able to catch something and get the bolt to turn out.
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Old 02-27-2012, 09:56 PM   #7
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Quote:
Originally Posted by rextech255 View Post
What I would do, is get a right angle pick and try to get the broken bolt loose. Go around the outside of the broke bolt in counterclockwise circles. You may be able to catch something and get the bolt to turn out.
and/or find a reversable right angle drill and some stubby left hand bits

I know they exist...I have used them

or pull the motor
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Old 02-28-2012, 01:11 PM   #8
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Scott's right. Reverse drive bits will work. It broke past the shoulder correct? If so there should be no tension holding it in. The reverse bit will spin it out once it finds a spot to grab. If you mess the threads on the head up just helicoil some new threads in. Your biggest issue will be space.

Either pull the engine or use a jack and lower the cradle a tad with everything attached. Just pull any lines that may over extend like fuel lines.
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Old 02-28-2012, 03:12 PM   #9
mod maniac
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I agree with the previous posts but also you could remove motor mount nuts and move the engine over for more room.
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Old 02-28-2012, 10:57 PM   #10
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pulling the motor would be the absolute best bet for visibility to center the bit
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