Broke a @%#$! intake manifold bolt. Aaaargh!
 

I was installing the intake manifold on a new rebuild and snapped a bolt. I was surprised at how low the torque is for the intake manifold and was trying to be careful. The bolt turned more than I thought it would but at low torque until it snapped.

Anyone dealt with extracting one of these suckers? Obviously I don't know yet if the threads are damaged, but if they are?

So pissed off. Everything was going really well until the moment it snapped.

Welcome to the club. Good luck getting it out. If you didn't intall the engine yet then just remove the LIM and take it to a machine shop.

It's still on the bench. Taking it to a machine shop is probably the smart thing so I don't screw it up worse.

I'm going to have to take of the intake manifold anyway, and taking off the exhaust manifold isn't a big deal, then at that point it will be transportable.

I've pulled out broken studs before and repaired aluminum blocks with helicoils, but it has been a long time (literally 20 years) and I am not looking forward to it.

Often they break because of the bolt stretching. ... so you might be able to get it out easily. If it is sticking out at all you should be able to just thread it out. It will be a lot easier than if it had corroded and you were trying to remove it.

Yeah mine broke removing it. Even the machine shop mangled the intake manifold getting it out. My buddy broke his tightening it, and it would not come out easily either. I now use anti-sieze on every bolt that enters aluminum, :lol:

I was that buddy :(

The torque to get it off was definitely higher (but not too bad) than the torque to install. It's possible the bolt may have been damaged a little coming out, but they all came out smoothly after the initial pop.

There is anti-seize on the threads and it went in easily, so there is some hope. It broke pretty far towards the end, but it has to pass through the manifold so I am not sure how much of the threads actually bite. Hopefully it broke flush or even sticking out slightly, but I won't know until I pull the manifold. It was getting dark when it happened last night and I was not in a particularly good frame of mind, so I decided to wait to pull the manifold.

It's a good thing my daughters were not around when it happened!

I did that to almost every bolt I touch, exhaust, manifold, whatever. cuz it's pain in the fxxxing ass to tap it. broken bolt SUCKS.

Anti-seize EVERYTHING lol. OR WD and a lot of patience. Sit down Relax, watch some TV work on another section. Just give the WD an hour or so.. And if you have the proper tools why not do it yourself. Yea it sucks but it saves you money in the long run. IF you know what your doing.

Crisis averted. Best case scenario. A piece of the bolt was sticking out just far enough to grab, and the anti-seize worked like a charm.

Threads look fine, bolt is out and no drilling. It is a good day!

Ugh just broke the hard to get at bolt on intake manifold! Fml, it broke trying to remove the Bolt, will easy outs help in this case or am I wasting my money?