Snapped screw extractor in sheared stud... suggestions?

[nstacey]

We've had an issue of a warped exhaust mannifold on Dad's TD5 Discovery. This is a fairly common thing on the td5 motor. The warped mannifold causes extra stress on the studs and as a result we sheared a couple of the studs when removing to get the mannifold reground. One was below the face of the head. We've drilled a hole and knocked in a screw extractor. Unfortunately used a size too small and thats now sheared at the face of the stud. Anyone got any suggestions what to do with it now, The extractor will be hardened steel so probably not an option to drill into it again?



Don't want to take the head off.

[Lynx]

Weld a nut to it, and undo it as a bolt, let the weld cool first though.

Cheers Daniel

[turoa]

or stick a plasma at it and zap it

[kbushnz]

I had the same issue a few years back.
Got a mate to TIG weld a smaller diameter bolt to the broken stud. Then I had something to hang a socket off.

Heated the alloy with a heat gun and kept spraying WD40 at her to get it to penetrate the threads. Then wait wait and wait.

Then heated the head with heat gun and fired a shot of Rapid freeze at the bolt.
Idea is to expand the alloy and shrink the steel bolt.
Lucky for me it came out.

Otherwise buy a Cruiser.!

Calvin

[mudlva]

I had the same issue a few years back.

Otherwise buy a Cruiser.!

Calvin

what he said
na seriously try the welding a bolt job if you can
good luck

[nstacey]

I had the same issue a few years back.

Otherwise buy a Cruiser.!

Calvin

what he said
na seriously try the welding a bolt job if you can
good luck

Yeah easier said than done, its an 8mm stud so no a lot of space to play with. Thanks for the suggestions will have another look at it tomorrow.

[wopass]

start by putting some saftey glasses on then get a good sized sharp centre punch, get it set spot on in the middle of the extractor and bash the fuk outa it, the extractor will shatter and then re drill bigger to about 2/3 the size of the bolt then use a bigger extractor.

or in a last ditch attempt you can get a small (2mm) drill and drill down the side of the bolt this will give you the ability to colapse the bolt and thus making it smaller enabling you to remaove said broken bolt...

or better yet get a cruiser

[mylux]

I did the same on the cruisers motor snapped an easy out in the block
Had my engineer come round with a carbon drill bit and drilled the whole lot out for me.
I think the carbon bits are fairly pricey though so it may pay to borrow one if you do go with this option.
Don't snap the carbon drill off in there though.

[corosafari]

Pretty much covered above

Spark eroder
Wack with punch
Cobalt drill bit

Next time use wire brush and penetrating oil, crc or inox on thread beforehand which can save alot of heartache, a bit of heat on a tight nut can help also though not always practicle in enginebay.

[dazza85]

I watched a guy once put a nut over the hole and mig weld down the centre because he could not get to the outside of the broken bolt

[turoa]

or better yet get a cruiser

Na they #### out on you and cost you what it would to buy a discovery which only have minor problems and tow just as hard as an 80

[BlackCruiser]

I had the same issue a few years back.

Otherwise buy a Cruiser.!

Calvin

what he said
na seriously try the welding a bolt job if you can
good luck

Yeah easier said than done, its an 8mm stud so no a lot of space to play with. Thanks for the suggestions will have another look at it tomorrow.

Done it heaps, same as the other guys said but we tig a nut on,

[pruggerdore]

I watched a guy once put a nut over the hole and mig weld down the centre because he could not get to the outside of the broken bolt

Would try this. has worked for me before

[pruggerdore]

progress report ???

[nstacey]

Cheers for the advice here guys, Welding a nut to the end of the stud was the solution we used in the end.