Offroad-Express

pulled air cleaner , heat shield , exhaust manifold found lose nuts a few exhaust leaks an a broken stud

taken first section of the exhuast pipe off,
ground clearance for the DSR manifold to fit

have a little cleanance problem here too

a shot of it mocked up

took rocker cover off for inspection

sump off too needs a bit of a clean only slight sludge build up

engine has got skirt oil squirters

Nice good to see bud!!

are you getting pump rebuilt or try it without rebuild first? how many kms has your engine done, mine has done 288,000 and i was a bit concerned with fitting the turbo but having said that i have the last 12 years worth of extensive regular servicing paperwork so think it should be ok.

yes pulling the pump for moddding , got someone lined up for that
mines 230 kms that why gone for lower psi

more boost!!! liking all this tech stuff

hey first time for alota shit for me badnuz

Its always that bloody stud at the back at the bottom that breaks to

Get a phenumatic drill (co's its small) and drill the fawker out, Heli coil or tap. Murphy says you WILL snap the "easy out" off in there, making drilling it out even harder

good idea have a small air drill at work too but not a reverser, injectors out tomorrow nite too so i can turn the bugger over

Unless your getting the injectors serviced, pulling the glow plugs is the better option if you just want to turn the motor over

arhhh, stud hardened! drill will not bite into it

Go buy yourself a Masonary drill bit from place makers/bunnings, the ones with the Tungsten Carbide tip, re-shape/sharpen the end for drilling steel, and try that.

I have re-drilled two complete spring packs with one re shaped masonary drill bit, so could possibly do the trick!!!

Cost ya $10 bucks to try it anyways

yes worth a go will try the mig way torrow nite , need to read up more on pump removal
oh pete the glow pug idea worked sweet

If all the above fails coxsy,we have a small collection of cobalt drills onboard that we use for drlling broken studs out , there not cheap but should work providing access ok , always the back one aye.

I will be going on leave from this wed morning heading for coro so let us know and I can probably drop one off for you to try , confirm stud size for us , were they @ 10mm ?

thanks for that, not much room to drill, got $127.00 90* angle drill attachment, so needs short drill bit, yes 10mm stud, if shit hits the fan, will pull the head to get it done
most stuff with this truck i can do even if i ask questions first, for me this is a steep learning curve

had to take off the fuel lines, to get one more nut undone, pump unbolted drive gear a non mover, more stuff to remove to get that off managed to get a 3mm hole in the stud end now wait till tomorrow as non of me easyouts fit
arh whats the rush anyway

Arrg, the easy out WILL snap!!!!

They always do

the stud is two threads in, fa to weld to, so unless i go to bigger drills to get the whole stud out, its a fair pain in the butt, all so drain the radiator , and pull it out so i can get a puller in there for the drive gear,nothing has been touched on this engine for years
can try those reverse type drill outs instead

If you can drill the stud to 6-8mm you can cut it with a hacksaw and collapse it, then pull it out with a magnet.

Cheers Daniel

maybe its a 10mm stud

DieselBoy wrote:Arrg, the easy out WILL snap!!!!

They always do

agreed i honestly cant think of the last time i had one work, the only time they really work is when things are not "that" stuck to start with. You've done the hard work and got a hole in it, drill the bitch out and helicoil it, or tap it if your that way inclined.

When you snap your easy out off in it then what ya gona do? your basically fu#ked, they are a real pain in the ass to drill out.

Remember a few years back on here someone talking about heating up the broken stud, touching it with a candle to run wax into the thread and just windind it out. Never tried it myself but would love to have a go one of these days. Open flames and highly explosive chemicals do NOT go together in my work so havent had the chance to try it.

easyouts are a pain. if you tryto hard with them, they are part of my work in maintance, broke a few, shatter the pieces and try another way

If you have already drilled bit of a pilot hole , get a good quality 8mm drill , thats slightly smaller than the tapping drill size so providing initial hole is center , you wont damage thread to much.
Remove remaining bits as suggested previous then run correct size tap down if you need to. The pitch should be 1.25 or 1.5mm depending on fine or course.

All easy outs are equal
Some are just more equal than others

If you break one off in the hole you have made things tricky

If I am going to pull something to bits and nuts and bolts look like they haven't been touch for ages I spray with crc, inox or similarthe day before and again when starting the job , after a bit of wire brushing. Believe me it helps.

don't think this engine has been touched in years

What have you guys been doing with thoughs easyouts? I've only ever broken one (sorry Dad) and really that was to small for what I was trying to do.

Unfortantly the pilot hole isn't exactly in the center of the stud due to its placement so puting an 8mm down it could be intreasting

that turbo setup is looking sweet, you will wonder why you havent done it before now. so are you getting some injector pump work done? bigger plunger? going to through an intercooler at it?? keep up the good work!!

well intercooler is in the think tank injector pump will be off soon for a boost compo
yes had the kit for over 3months but 4wd got in the way

What inter cooler setup are you using?

Take your time to get it all done right so when you come do mine it will happen without a hitch

thinking of one of those tube water air inter coolers, no hole in the hood, no fan to worry about, its a quiet time club wise , so it a good time to get this done plus get the whole thing certed out of the way as wof is due next month

do you have to cert since some models where turbo induction?