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Old 12-30-2013, 02:51 AM   #1
DwntheRabbitHole
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Default Corrosion on newish bolts and boost leak. YES!!

I have a 2011 WRX, and I installed my new PW TMIC tonight. Everything was going great until I accidentally broke a bolt trying to remove it from the turbo housing! Upon removing the broken bolt it was obvious that severe corrosion was the cause of weakness of the metal, which is really confusing to me. Like I said, my WRX is a 2011 AND I only have 39k miles on it. I live on the east coast so harsh weather/road salt plagues us over here but damn... Kinda seems like a quality control issue on Subaru's end.

I decided to finish the install since I was already basically done removing the oem tmic. I got everything bolted up and tightened and was just crossing my fingers that I wouldn't have an issue with the missing bolt, but upon my initial, and only, drive I noticed a MASSIVE boost leak and my a/f levels were all over the place. I figured this would happen but I was just hoping I would get lucky I guess. What a freaking headache.

So, my question is: Who knows any good tricks to removing a broken bolt that is stuck within threading?

I know that I can drill it out, but I don't have the appropriate tools for that. Do I need to take it to the shop and have this done or is there an easier, and cheaper, way out there. Thanks for the consideration...
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Old 12-30-2013, 04:28 AM   #2
HeroCrank
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If you don't have the appropriate tools, then its off to the garage you go.

There are two diy options for this very common issue.

1. Drill and tap a new hole for new hardware.

2. Drill the rest of the bolt out and use a longer bolt with a nut and the appropriate hardware to fix your leak.
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Old 12-30-2013, 04:47 AM   #3
DwntheRabbitHole
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Yeah, saw that on YouTube. Thanks though.
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Old 12-30-2013, 06:24 AM   #4
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soak in liquid wrench and drill it out and use a broken bolt extractor
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Old 12-30-2013, 09:40 AM   #5
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Quote:
Originally Posted by Uncle Scotty View Post
soak in liquid wrench and drill it out and use a broken bolt extractor
Bolts that are stuck from corrosion almost always mean you're going to break off the extractor in the bolt. If you broke it from over torquing it without bottoming it out, extractors work great. If its not a bolt that requires super high strength I would just drill the bolt through with the tap drill size for the thread and run the tap through it. Do note that this will almost always result in the threads having a reduced minor diameter and not being as strong.
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Old 12-30-2013, 10:50 AM   #6
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Quote:
Originally Posted by Leafy View Post

Bolts that are stuck from corrosion almost always mean you're going to break off the extractor in the bolt. If you broke it from over torquing it without bottoming it out, extractors work great. If its not a bolt that requires super high strength I would just drill the bolt through with the tap drill size for the thread and run the tap through it. Do note that this will almost always result in the threads having a reduced minor diameter and not being as strong.
If you're really good, you could use one size smaller and pick out the remnants. Probably one and a million on the car. Setting it up on a mill or drill press would be a different story.
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Old 12-30-2013, 11:04 AM   #7
JimmyBoyWRX
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Quote:
Originally Posted by Uncle Scotty View Post
soak in liquid wrench and drill it out and use a broken bolt extractor
This

Just don't buy a knock off cheap one and it will work fine.
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Old 12-30-2013, 01:23 PM   #8
DwntheRabbitHole
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Ok I will give it a shot. Thanks for all the advice. Feeling pretty defeated that one damn corroded bolt stopped me from enjoying my new mod lol
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Old 12-30-2013, 02:37 PM   #9
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What were you removing from the turbo housing while swapping the TMIC?
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Old 12-30-2013, 02:39 PM   #10
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Quote:
Originally Posted by danny_d19 View Post
What were you removing from the turbo housing while swapping the TMIC?
I'm assuming he has an 08+ WRX, so it should be self explanatory what bolt he broke since its somewhat common.
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Old 12-30-2013, 05:36 PM   #11
dead_eye
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After soaking the bolt with KROIL or PBLASTER, you can try and drill the bolt out with a LEFT hand drill bit.

http://www.harborfreight.com/13-piec...set-95146.html

If you really get it stuck, there's left hand taps you can thread the hole you drilled in the broken bolt, then use a matching left hand bolt to turn it out.
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Old 12-30-2013, 08:32 PM   #12
DwntheRabbitHole
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All of these ideas sound rational, but I think I'm just going to take it in to the shop. If I end up having to re-thread it or god forbid I drop metal shards into the compressor housing, I would at that point be working out of my comfort zone.

Next question, my car seems to run fine as long I don't boost at all. The shop I trust to do the work is about 30 miles away. Do you guys think operating with such extensive boost leak could pose a damaging situation during my travel?
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Old 12-30-2013, 08:49 PM   #13
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Quote:
Originally Posted by Leafy View Post
Bolts that are stuck from corrosion almost always mean you're going to break off the extractor in the bolt. If you broke it from over torquing it without bottoming it out, extractors work great. If its not a bolt that requires super high strength I would just drill the bolt through with the tap drill size for the thread and run the tap through it. Do note that this will almost always result in the threads having a reduced minor diameter and not being as strong.

id bet ya a dolla i could get it out unless it is fused solid

it might take an hour or 3 but it WOULD come OUT
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Old 12-30-2013, 08:51 PM   #14
JonnyV2889
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Quote:
Originally Posted by Uncle Scotty View Post

id bet ya a dolla i could get it out unless it is fused solid

it might take an hour or 3 but it WOULD come OUT
It's all about the back and fourth action and lubrication... Maybe some heat...
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Old 12-30-2013, 09:19 PM   #15
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Quote:
Originally Posted by JonnyV2889 View Post
It's all about the back and fourth action and lubrication... Maybe some heat...

yeah...bein that heat is what caused the issue, heat is what(part of what) will solve it
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Old 12-30-2013, 09:22 PM   #16
DwntheRabbitHole
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But can I drive on it for about 30 miles safely
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Old 12-30-2013, 09:59 PM   #17
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Quote:
Originally Posted by DwntheRabbitHole View Post
But can I drive on it for about 30 miles safely

sure...just dont beat on it...

dont try to make it make boost...it will just go super rich and fall on its face and maybe overspeed the terbo and blow that up if ya do hammer it

so dont
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Old 12-31-2013, 05:19 PM   #18
DwntheRabbitHole
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Ended up going to a local tuning ship and had them fix it. I didn't want to end up getting any metal shards from the bolt into the turbo housing lol
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