Hello everyone.

I really need some help here. To make a long story short I tried to torque a bolt to the required spec, 16 ft lbs and it broke before the torque wrench clicked. Now the rest of the bolt is deep into the block/rocker assembly, about 3 inches. I have heard of an easy out, but I can't find one that is long enough. Even worse, most require a drill of some sort and I can't fit one in there because of the windshield. You should understand after I give you guys some pictures.

I talked to a mechanic and he said that I need to take the head off or maybe the rocker assembly, but that is wayyyyy out of my league and I don't have the several hundred dollars it costs to do that. Please, I really need your help.

Here on the pictures:

First, I'll show you what I'm dealing with.




The red circle is where the bolt should be and where the bottom of the bolt is and broke off. The green circles are the bolts that are like it.

Now, here is a closer view of how the windshield is blocking everything and not giving me enough room. I put a small screwdriver down the hole for reference.





Last, is the actual bolt that broke. The first one broke on the top where the valve cover sits so then I replaced it with the other bolt and that's when the bottom of that bolt broke. As you can see, it broke roughly 3 inches deep in there.




Here's a diagram to get a better look:




That's all I've got. I hope someone here as some advice on how to get the rest of the bolt out. I'm pretty torn up about this and my stomach hurts from all the chaos this has caused.

Thanks

 

take out the other 3 bolts and remove that piece then post a pic of that so i can see what it looks like

you may have to take all the other ones loose to to make sure you don't damge anything so it's not out os sequance

 

I already took the cam retainer out. It looks like this, but with the camshafts and the other cam retainers in.

If you need a pic I'll certainly get one.

 

pull the cam retainers off your motor i'm guessing you could be lucky and have a little bit of the broken bolt sticking out of the head if not it will give you alittle more room to try to get a easy out in it

 

is a little bit is sticking up, i wouldn't waste time trying to grab it with pliers. have a friend with a tig welder weld another bolt onto the stub and try to back it out, otherwise you would need to remove the head and send it to a shop to take it out. chances are it would get messed up if you try to use an easy out your self.

 

What you are going to have to do is remove the cams to access the bolt. Luckily enough for you i highly down you bottomed it out so you may get lucky and be able to use a chisle and back it out with the peiece that broke "upwards". It is kind of a pain in the *** since you are going to have re time your engine since your removing the cams. make sure you have the bottom end set at TDC and it will make your life alittle bit easier. Once you have the cams off, zip tie the rockers together so that you dont lose any of the pins and springs inbetween them. Remove the 2 10's next to the cam position sensors that hold the final cast to the head and pull up. it may be alittle difficult since the "bridges(for the cam)" are doweled. that will allow you to get to the bottom where that bolt is broken off too. Its kind of hard to explain but it is aittle time/knowledge intensive so if you dont think you can do it bring it down to dallas and we (viktek) can try to get it out for you :-p Goodluck man.

 

if yu look here you can see what im talking about. the whole rocker shaft assembly can and will come off, just ziptie each set of rockers together and then the bridges together if you want to make it alittle bit easier.