Well, when I was taking off the exh mani heat shield a while back, one of the bolt heads broke off (the center top one). I need to get the rest of the bolt out so i can install the new shield. I wanted to get a tap in there to extract it, but the angle doesnt work. My options are to either remove the manifold, or the radiator. I think getting the radiator out will be easier, however I haven't fiddled with those components much. Is it possible to just undo the connections (hoses, bolts, wires) and pull it out the top as a unit? That should give enough room to get a drill in there.
Any comments?

juan

...since I've never removed the radiator before. With all that you've done to your car it wouldn't be bad. If I had the choice I would remove the radiator though. It would be a good time to flush it or maybe just realpace the coolant. Essentially it is like you said just remove the upper and lower hose and a few bolts. I would think it to be easier than the manny

removing radiator = easy

its like 2-4 bolts a couple of hoses and some harness connectors.

cool. thats what I thought.

juan

Yeah, nothing to it - once you disconnect the radiator hoses and fan harness connectors, there are only two bolts per bracket that hold it on. After that, it lifts out. There is nothing onthe bottom that hold is in save the lower radiator hose and the pressure from the upper mount brackets.

yeah radiator will be a snap for you. four bolts and a couple hose clamps. I assume you mean the bolt on the front then? Not the top? of the manifold. Try to use an extractor first. drill through the bolt and then turn the extractor in. You might be able to pull the bolt out without having to tap to a bigger size thread.

Una salus victus.



Michael J. Kulaga
e-mail: Michael_97RS@2gntDSM.zzn.com aol IM: MJKulga
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welp, I got the rad off without any difficulty. Surprisingly simple, actually.

I am trying to bore out the hole so I can get one of those reverse-thread extractors in. Broke all three damn bits I had in the proper size. Have to get a good set of hardened ones now. I also found out the extractor is too small for the tap I bought. Gotta see if Lowes has the next smaller size.

I was definitely too optimistic thinking I could get it all done in an hour last night... :/

juan

Funny how that happens. I end up in that situation so much..

Too bad you're way over there and i'm way over here. I'd give you a hand.

So once I got the extractor in place, I tried turning it. Then the effer snapped! So now I've got a chunk of hardened metal in the hole. The cobalt drill bit doesn't do anything to this material either. Is there an even harder drill material?

It's getting to the point where I'll just have to take the manifold off and have it fixed at a shop. Anyone know the going rate on a used manifold? Maybe it'll be worth it to just get another one (and maybe have it ported).

Oh, and the extractor is ok, i didnt see the smaller size part on the inside.

Thanks for the offer Dino. If you fly out here to help, I'll buy you dinner or something. I hear Southwest has cheap flights... ;)

juan

It's funny because we had to do all of that mentioned yesteday on Dino's car... two bolts broke off on THE turbo. woah

damn Juan. If you need a loaner exhaust manifold, just let me know. i got one lying around that you can borrow.

I have one laying around as well if it turns out you need it..

Generally i have learned (especially in the last few days) that if a bolt has snapped off in your manifold/turbo/turbo manifold then nothing short of drilling it out is going to get it out. it is much, much worse to break off the extractor in it than to have to chase the threads with a tap (or over-drill it and just retap it) and much easier to deal with...

Don't feel too bad, i snapped two bolts of in my turbine housing yesterday and got to do all this, too.