Previous Owner Broke Valve Cover Bolt - Ford Powerstroke Diesel Forum
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Old 07-27-2014, 09:05 AM

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Previous Owner Broke Valve Cover Bolt

My buddy bought a 2005 F-250 6.0 last month. A local dealer was dumping it off cheap cause his "mechanic" suspected it had bad Headgaskets. Headgaskets ended up being fine. But this truck is a basket case!

Back to the problem at hand.

I did an oil cooler for my buddy cause his deltas were a little over 15 degrees. I noticed the drivers side valve cover was coated in RTV. So I took the valve cover off to inspect the situation.

One bolt was lost and a new coarse thread bolt was forced in so that hole is all messed up.

Then I noticed that the bottom center bolt was not there and just RTV'd over top. When I pulled the "RTV plug" that had for formed in the hole out I saw that the previous owner had broken then bolt off and poorly attempted to drill it out.

I'm at a crossroads here if what I should to to repair this issue. Try to drill it out and over size it? Just RTV back over the hole like the previous owner and hope for the best?

Keep in mind this engine was caked in oil and sludge. I spent nearly 8 hours scraping and scrubbing to remove all the oil and sludge that was all over the engine. So I'm hoping for no oil leaks when I put it back together.

On a side note I was planning to post the tear down pictures to show you guys how bad it was. So many bolts loose, finger tight, over tight, so loose they were just laying next to where they went as if they had vibrated out of their hole, etc.
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