Re: bolt extractor - contributing to list wisdom - Saab NG900 & OG9-3 Bulletin Board - Saabnet.com
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Re: bolt extractor - contributing to list wisdom
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Posted by bill h. (more from bill h.) on Mon, 8 Nov 2004 08:25:17 Share Post by Email
In Reply to: bolt extractor - contributing to list wisdom, Paul Nielsen, Mon, 8 Nov 2004 05:23:10
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Couple years ago when I had discovered two broken studs on the far drivers side cylinder (and my mechanic told me $800.00 to remove the head and send to a machine shop), I set out to do the same thing with high quality cobalt left hand (reverse) drill bits and a collar to fit in the manifold hole. I even had a right angle Makita drill, so no need to remove fan or shroud. I soaked the studs with PB blaster in hope that would help free them up.

I was not able to drill all the way through the stud and the left hand drill did not free the studs during drilling. After drilling 10-12mm deep using a guide collar in the manifold I was horrified to observe that the hole was off center in both. Turns out that the studs must have been broken for awhile (damn noisy sport exhaust installed 1.5 years earlier) and I never heard the leak until the exhaust gasket was completely eaten up. The manifold holes did not line up with the broken studs! The manifold port and holes had permanently shifted about 3-4mm to the right. I tried to remove them in vain with the miracle Sears Craftsman extractor kit and woud up breaking off the extractor in the stud. Hard to redrill with tool steel imbedded. So three years and 45k later, they are still broken. I dont really hear the leak thanks in part to the noisy Saab sport exhaust. No other damage and car still runs fine.

Not a satisfying end to the story, but just to let you know what might happen with broken studs left in place for a long period of time and as a warning for all to first check broken studs with flashlight and mirror to assure that your manifold has not crept out of alignment before using the manifold holes as centering drill guides.

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